69NT40-511-300 to -399, excluding 310, 344 & 359.pdf

Page 1 of 122

Container Refrigeration

T--285 Rev H

OPERATION AND SERVICE

for

69NT40--511--300 to 399

(excluding --310, --344 & --359)

Container Refrigeration Units

Page 2 of 122

Page 3 of 122

OPERATION AND SERVICE MANUAL

CONTAINER REFRIGERATION UNIT

69NT40--511--300 to 399

(excluding --310, --344 & --359)

Page 4 of 122

Safety-1 T-285

SAFETY SUMMARY

GENERAL SAFETY NOTICES

The following general safety notices supplement the specific warnings and cautions appearing elsewhere in this

manual. They are recommended precautions that must be understood and applied during operation and maintenance

of the equipment covered herein. The general safety notices are presented in the following three sections labeled:

First Aid, Operating Precautions and Maintenance Precautions. A listing of the specific warnings and cautions

appearing elsewhere in the manual follows the general safety notices.

FIRST AID

An injury, no matter how slight, should never go unattended. Always obtain first aid or medical attention immediately.

OPERATING PRECAUTIONS

Always wear safety glasses.

Keep hands, clothing and tools clear of the evaporator and condenser fans.

No work should be performed on the unit until all circuit breakers, start-stop switches are turned off, and power supply

is disconnected.

Always work in pairs. Never work on the equipment alone.

In case of severe vibration or unusual noise, stop the unit and investigate.

MAINTENANCE PRECAUTIONS

Beware of unannounced starting of the evaporator and condenser fans. Do not open the condenser fan grille or

evaporator access panels before turning power off, disconnecting and securing the power plug.

Be sure power is turned off before working on motors, controllers, solenoid valves and electrical control switches. Tag

circuit breaker and power supply to prevent accidental energizing of circuit.

Do not bypass any electrical safety devices, e.g. bridging an overload, or using any sort of jumper wires. Problems with

the system should be diagnosed, and any necessary repairs performed, by qualified service personnel.

When performing any arc welding on the unit or container, disconnect all wire harness connectors from the modules in

both control boxes. Do not remove wire harness from the modules unless you are grounded to the unit frame with a

static safe wrist strap.

In case of electrical fire, open circuit switch and extinguish with CO2 (never use water).

UNIT LABEL IDENTIFICATION

To help identify the label hazards on the unit and explain the level of awareness each one carries, an explanation is

given with the appropriate consequences:

DANGER -- means an immediate hazard which WILL result in severe personal injury or death.

WARNING -- means to warn against hazards or unsafe conditions which COULD result in severe personal injury or

death.

CAUTION -- means to warn against potential hazard or unsafe practice which could result in minor personal injury,

product or property damage.

SPECIFIC WARNING AND CAUTION STATEMENTS

The statements listed below are applicable to the refrigeration unit and appear elsewhere in this manual. These

recommended precautions must be understood and applied during operation and maintenance of the equipment

covered herein.

WARNING

Beware of unannounced starting of the evaporator and condenser fans. The unit may cycle the fans

and compressor unexpectedly as control requirements dictate.

WARNING

Do not attempt to remove power plug(s) before turning OFF start-stop switch (ST), unit circuit break- er(s) and external power source.

WARNING

Make sure the power plugs are clean and dry before connecting to any power receptacle.

Page 5 of 122

T-285 Safety-2

SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued

WARNING

Make sure that the unit circuit breaker(s) (CB-1 & CB-2) and the START-STOP switch (ST) are in the

“O” (OFF) position before connecting to any electrical power source.

WARNING

Never use air for leak testing. It has been determined that pressurized, mixtures of refrigerant and air

can undergo combustion when exposed to an ignition source.

WARNING

Make sure power to the unit is OFF and power plug disconnected before replacing the compressor.

WARNING

Before disassembly of any external compressor component make sure to relieve possible internal

pressure by loosening the bolts and tapping the component with a soft hammer to break the seal.

WARNING

Do not use a nitrogen cylinder without a pressure regulator. Do not use oxygen in or near a refrigera- tion system as an explosion may occur.

WARNING

Do not open the condenser fan grille before turning power OFF and disconnecting power plug.

WARNING

Oakite No. 32 is an acid. Be sure that the acid is slowly added to the water. DO NOT PUT WATER INTO

THE ACID -- this will cause spattering and excessive heat.

WARNING

Wear rubber gloves and wash the solution from the skin immediately if accidental contact occurs. Do

not allow the solution to splash onto concrete.

WARNING

Always turn OFF the unit circuit breakers (CB-1 & CB-2) and disconnect main power supply before

working on moving parts.

WARNING

Make sure power to the unit is OFF and power plug disconnected before removing capacitor(s).

WARNING

With power OFF discharge the capacitor before disconnecting the circuit wiring.

WARNING

The unit power plug must be disconnected to remove power from circuit breaker CB1

CAUTION

Do not remove wire harnesses from controller unless you are grounded to the unit frame with a static

safe wrist strap.

CAUTION

Unplug all controller wire harness connectors before performing arc welding on any part of the con- tainer.

Page 6 of 122

Safety-3 T-285

SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued

CAUTION

Pre-trip inspection should not be performed with critical temperature cargoes in the container.

CAUTION

When Pre-Trip key is pressed, dehumidification and bulb mode will be deactivated. At the comple- tion of Pre-Trip activity, dehumidification and bulb mode must be reactivated.

CAUTION

When condenser water flow is below 11 lpm (3 gpm) or when water-cooled operation is not in use, the

CFS switch MUST be set to position ”1” or the unit will not operate properly.

CAUTION

When a failure occurs during automatic testing the unit will suspend operation awaiting operator

intervention.

CAUTION

When Pre--Trip test Auto 2 runs to completion without being interrupted, the unit will terminate pre- trip and display “Auto 2” “end.” The unit will suspend operation until the user depresses the ENTER

key!

CAUTION

The unit will remain in the full cooling mode as long as the emergency bypass switch is in the BY- PASS position. If the cargo may be damaged by low temperatures, the operator must monitor con- tainer temperature and manually cycle operation as required to maintain temperature within required

limits.

CAUTION

The unit will remain in the DEFROST mode as long as the emergency defrost switch is in the DE- FROST position. To prevent cargo damage, the operator must monitor container temperature and

manually cycle operation as required to maintain temperature within required limits.

CAUTION

To prevent trapping liquid refrigerant in the manifold gauge set be sure set is brought to suction

pressure before disconnecting.

CAUTION

Removing the compressor motor press-fit stator in the field is not recommended. The rotor and sta- tor are a matched pair and should not be separated.

CAUTION

The copper tube which connects to the oil suction strainer extends out the bottom with the bottom

plate removed. Take precautions to avoid bending or breaking it while changing crankcase posi- tions.

CAUTION

Ensure that thrust washer does not fall off dowel pins while installing oil pump.

CAUTION

The set screw on the crankshaft must be removed for this type of oil pump.

CAUTION

Use only Carrier Transicold approved Polyol Ester Oil (POE) -- Mobil ST32 compressor oil with

R-134a. Buy in quantities of one quart or smaller. When using this hygroscopic oil, immediately

reseal. Do not leave container of oil open or contamination will occur.

Page 7 of 122

T-285 Safety-4

SPECIFIC WARNING AND CAUTION STATEMENTS -- Continued

CAUTION

Take necessary steps (place plywood over coil or use sling on motor) to prevent motor from falling

into condenser coil.

CAUTION

If the thermostatic expansion valve is found to be in need of replacement, then the power head and

cage assembly are to replaced as a pair. They are a matched pair and replacing one without the other

will affect the superheat setting.

CAUTION

DO NOT disassemble piston from NEW suction modulating valve powerhead assembly. Doing so

may result in damage to piston.

CAUTION

The unit must be OFF whenever a programming card is inserted or removed from the controller pro- gramming port.

CAUTION

All 69NT40-511-3XX units must use software revision 5108 or higher to enable stepper motor.

Optional features may require higher software revision levels to enable functionality.

CAUTION

Do not allow moisture to enter wire splice area as this may affect the sensor resistance.

CAUTION

Do not allow the recorder stylus to snap back down. The stylus arm base is spring loaded, and

damage may occur to the chart, or the stylus force may be altered.

CAUTION

The inside mechanism of the recorder, particularly the inside of the element housing should never be

oiled, however, control mechanisms should be sprayed periodically (every 60 days) with corrosion

inhibiting CRC 3-36a or 6-66 or LPS no. 2.

CAUTION

Recorder element capillary tubing may be bent, but never sharper than 1/2” radius; extra care should

be taken when bending adjacent to welds. The bulb should never be bent, as this will affect

calibration.

Page 8 of 122

i T-285

TABLE OF CONTENTS

PARAGRAPH NUMBER Page

GENERAL SAFETY NOTICES Safety-1 .......................................................

FIRST AID ........................................................................ Safety-1

OPERATING PRECAUTIONS Safety-1 .......................................................

MAINTENANCE PRECAUTIONS Safety-1 .....................................................

UNIT LABEL IDENTIFICATION Safety-1 ......................................................

SPECIFIC WARNING AND CAUTION STATEMENTS Safety-1 ...................................

INTRODUCTION .............................................................................. 1-1

1.1 INTRODUCTION ..................................................................... 1-1

1.2 CONFIGURATION IDENTIFICATION 1-1 ...................................................

1.3 OPTION DESCRIPTION .............................................................. 1-1

1.3.1 Battery ........................................................................... 1-1

1.3.2 Dehumidification .................................................................. 1-1

1.3.3 Control Box ...................................................................... 1-1

1.3.4 Temperature Readout .............................................................. 1-1

1.3.5 Pressure Readout ................................................................. 1-1

1.3.6 USDA ........................................................................... 1-1

1.3.7 Interrogator ....................................................................... 1-1

1.3.8 Remote Monitoring ................................................................ 1-1

1.3.9 Communications. .................................................................. 1-1

1.3.10 Compressor ...................................................................... 1-1

1.3.11 Condenser Coil ................................................................... 1-2

1.3.12 Autotransformer ................................................................... 1-2

1.3.13 Temperature Recorder ............................................................. 1-2

1.3.14 Gutters .......................................................................... 1-2

1.3.15 Handles .......................................................................... 1-2

1.3.16 Thermometer Port ................................................................. 1-2

1.3.17 Water Cooling .................................................................... 1-2

1.3.18 Back Panels ...................................................................... 1-2

1.3.19 460 Volt Cable ................................................................... 1-2

1.3.20 230 Volt Cable .................................................................... 1-2

1.3.21 Cable Restraint ................................................................... 1-2

1.3.22 Upper Air (Fresh Air Make Up) 1-2 ......................................................

1.3.23 Lower Air (Fresh Air Make Up) 1-2 ......................................................

1.3.24 Controlled Atmosphere ............................................................. 1-2

1.3.25 Arctic Mode ...................................................................... 1-2

1.3.26 Humidification .................................................................... 1-2

1.3.27 Power Correction .................................................................. 1-2

1.3.28 Evaporator ....................................................................... 1-2

1.3.29 Evaporator Fan Operation 1-3 ..........................................................

1.3.30 Labels ........................................................................... 1-3

1.3.31 Plate Set ......................................................................... 1-3

1.3.32 Controller ........................................................................ 1-3

1.3.33 Condenser Grille .................................................................. 1-3

1.3.34 Emergency Bypass ................................................................ 1-3

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T-285 ii

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

DESCRIPTION ............................................................................... 2-1

2.1 GENERAL DESCRIPTION ............................................................. 2-1

2.1.1 Refrigeration Unit -- Front Section 2-1 ...................................................

2.1.2 Fresh Air Makeup Vent ............................................................. 2-1

2.1.3 Evaporator Section ................................................................ 2-2

2.1.4 Compressor Section ............................................................... 2-3

2.1.5 Air Cooled Condenser Section 2-4 ......................................................

2.1.6 Water-Cooled Condenser Section 2-5 ...................................................

2.1.7 Control Box Section ............................................................... 2-6

2.1.8 Communications Interface Module 2-6 ...................................................

2.2 REFRIGERATION SYSTEM DATA 2-7 ......................................................

2.3 ELECTRICAL DATA ................................................................... 2-8

2.4 SAFETY AND PROTECTIVE DEVICES 2-9 .................................................

2.5 REFRIGERATION CIRCUIT 2-10 ...........................................................

MICROPROCESSOR .......................................................................... 3-1

3.1 TEMPERATURE CONTROL MICROPROCESSOR SYSTEM 3-1 ..............................

3.1.1 Key Pad ......................................................................... 3-2

3.1.2 Display Module ................................................................... 3-2

3.1.3 Controller ........................................................................ 3-3

3.2 CONTROLLER SOFTWARE 3-3 ...........................................................

3.2.1 Configuration Software (Configuration

Variables) ............................................................................... 3-3

3.2.2 Operational Software (Function Codes) 3-3 ..............................................

3.3 MODES OF OPERATION ............................................................. 3-3

3.3.1 Temperature Control -- Perishable Mode 3-4 ..............................................

3.3.2 Evaporator Fan Operation 3-4 ..........................................................

3.3.3 Defrost Interval ................................................................... 3-4

3.3.4 Failure Action ..................................................................... 3-4

3.3.5 Generator Protection .............................................................. 3-4

3.3.6 Condenser Pressure Control 3-4 ........................................................

3.3.7 Arctic Mode ...................................................................... 3-4

3.3.8 Perishable Mode -- Conventional 3-4 ....................................................

3.3.9 Perishable Mode -- Economy 3-5 .......................................................

3.3.10 Perishable Mode -- Dehumidification 3-5 .................................................

3.3.11 Perishable, Dehumidification -- Bulb Mode 3-5 ............................................

3.3.12 Temperature Control -- Frozen Mode 3-6 .................................................

3.3.13 Frozen Mode -- Conventional 3-6 .......................................................

3.3.14 Frozen Mode -- Economy 3-6 ...........................................................

3.4 CONTROLLER ALARMS .............................................................. 3-6

3.5. UNIT PRE-TRIP DIAGNOSTICS 3-7 .......................................................

3.6 DataCORDER ........................................................................ 3-7

3.6.1 Description ....................................................................... 3-7

3.6.2 DataCORDER Software 3-7 ............................................................

3.6.3 Sensor Configuration (dCF02) 3-8 ......................................................

3.6.4 Logging Interval (dCF03) 3-10 ...........................................................

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iii T-285

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

3.6.5 Thermistor Format (dCF04) 3-10 .........................................................

3.6.6 Sampling Type (dCF05 & dCF06) 3-10 ...................................................

3.6.7 Alarm Configuration (dCF07 -- dCF10) 3-10 ...............................................

3.6.8 DataCORDER Power-Up 3-10 ...........................................................

3.6.9 Pre-Trip Data Recording 3-10 ...........................................................

3.6.10 DataCORDER Communications 3-10 .....................................................

3.6.11 USDA Cold Treatment ............................................................. 3-11

3.6.12 USDA Cold Treatment Procedure 3-11 ...................................................

3.6.13 DataCORDER Alarms ............................................................. 3-11

OPERATION ................................................................................. 4-1

4.1 INSPECTION (Before Starting) 4-1 .........................................................

4.2 CONNECT POWER .................................................................. 4-1

4.2.1 Connection To 380/460 vac Power 4-1 ...................................................

4.2.2 Connection to190/230 vac Power 4-1 ....................................................

4.3 ADJUST FRESH AIR MAKEUP VENT 4-1 ...................................................

4.3.1 Upper Fresh Air Makeup Vent 4-1 .......................................................

4.3.1 Fresh Air Vent Position Sensor (VPS) 4-2 ...............................................

4.3.2 Lower Fresh Air Makeup Vent 4-2 .......................................................

4.4 CONNECT WATER-COOLED CONDENSER 4-2 .............................................

4.4.1 Water--Cooled Condenser with Water Pressure Switch 4-2 .................................

4.4.2 Water-Cooled Condenser with Condenser Fan Switch 4-3 ..................................

4.5 CONNECT REMOTE MONITORING RECEPTACLE 4-3 ......................................

4.6 STARTING AND STOPPING INSTRUCTIONS 4-3 ...........................................

4.6.1 Starting the Unit ................................................................... 4-3

4.6.2 Stopping the Unit .................................................................. 4-3

4.7 START--UP INSPECTION ............................................................. 4-3

4.7.1 Physical Inspection ................................................................ 4-3

4.7.2 Check Controller Function Codes 4-3 ....................................................

4.7.3 Start Temperature Recorder 4-3 ........................................................

4.7.4 Complete Inspection ............................................................... 4-3

4.8 PRE-TRIP DIAGNOSIS ............................................................... 4-3

4.9 OBSERVE UNIT OPERATION 4-4 .........................................................

4.9.1 Crankcase Heater ................................................................. 4-4

4.9.2 Probe Check ..................................................................... 4-5

4.10 SEQUENCE OF OPERATION 4-5 ...........................................................

4.10.1 Sequence Of operation -- Perishable Mode Cooling 4-6 ....................................

4.10.2 Sequence Of Operation -- Perishable Mode Heating 4-7 ...................................

4.10.3 Sequence Of operation -- Frozen Mode Cooling 4-7 ........................................

4.10.4 Sequence Of Operation -- Defrost 4-7 ...................................................

4.11 EMERGENCY OPERATION 4-9 ...........................................................

4.11.1 Emergency Bypass Operation. 4-9 ......................................................

4.11.2 Emergency Defrost Operation. 4-9 ......................................................

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T-285 iv

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

TROUBLESHOOTING ......................................................................... 5-1

5.1 UNIT WILL NOT START OR STARTS THEN STOPS 5-1 ......................................

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING 5-1 ..............................

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING 5-2 ........................................

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING 5-2 ................................

5.5 UNIT WILL NOT TERMINATE HEATING 5-2 ................................................

5.6 UNIT WILL NOT DEFROST PROPERLY 5-2 ................................................

5.7 ABNORMAL PRESSURES (COOLING) 5-3 .................................................

5.8 ABNORMAL NOISE OR VIBRATIONS 5-3 ..................................................

5.9 CONTROLLER MALFUNCTION 5-3 ........................................................

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW 5-4 ..............................

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION 5-4 ...................................

5.12 AUTOTRANSFORMER MALFUNCTION 5-4 ................................................

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH 5-4 ........................

SERVICE .................................................................................... 6-1

6.1 SECTION LAYOUT ................................................................... 6-1

6.2 SERVICE VALVES .................................................................... 6-1

6.3. MANIFOLD GAUGE SET .............................................................. 6-1

6.4 PUMPING THE UNIT DOWN 6-2 ..........................................................

6.5 REFRIGERANT LEAK CHECKING 6-3 .....................................................

6.6 EVACUATION AND DEHYDRATION 6-3 ....................................................

6.6.1 General .......................................................................... 6-3

6.6.2 Preparation ....................................................................... 6-3

6.6.3 Procedure - Complete system 6-3 .......................................................

6.6.4 Procedure - Partial System 6-4 .........................................................

6.7 REFRIGERANT CHARGE ............................................................. 6-4

6.7.1 Checking the Refrigerant Charge 6-4 ....................................................

6.7.2 Adding Refrigerant to System (Full Charge) 6-4 ...........................................

6.7.3 Adding Refrigerant to System (Partial Charge) 6-4 ........................................

6.8 COMPRESSOR ...................................................................... 6-5

6.8.1 Removal and Replacement of Compressor 6-5 ...........................................

6.8.2 Compressor Disassembly 6-6 ..........................................................

6.8.3 Compressor Reassembly 6-8 ...........................................................

6.8.4 Preparation ....................................................................... 6-8

6.8.5 Installing the Components 6-9 ..........................................................

6.8.6 Compressor Oil Level .............................................................. 6-9

6.9 HIGH PRESSURE SWITCH 6-10 ...........................................................

6.9.1 Replacing High Pressure Switch 6-10 .....................................................

6.9.2 Checking High Pressure Switch 6-10 .....................................................

6.10 CONDENSER COIL .................................................................. 6-10

6.11 CONDENSER FAN AND MOTOR ASSEMBLY 6-10 ...........................................

6.12 WATER COOLED CONDENSER CLEANING 6-10 ............................................

6.13 FILTER-DRIER ....................................................................... 6-12

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v T-285

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

6.14 THERMOSTATIC EXPANSION VALVE 6-12 ..................................................

6.14.1 Checking Superheat. .............................................................. 6-13

6.14.2 Hermetic Valve Replacement 6-13 .......................................................

6.14.3 Semi--Hermetic Valve Replacement 6-14 ..................................................

6.15 EVAPORATOR COIL AND HEATER ASSEMBLY 6-15 .........................................

6.15.1 Evaporator Coil Replacement 6-15 .......................................................

6.15.2 Evaporator Heater Replacement 6-15 ....................................................

6.16 EVAPORATOR FAN AND MOTOR ASSEMBLY 6-15 ..........................................

6.16.1 Replacing The Evaporator Fan Assembly 6-15 .............................................

6.16.2 Disassemble The Evaporator Fan Assembly 6-15 ..........................................

6.16.3 Assemble The Evaporator Fan Assembly 6-15 .............................................

6.17 EVAPORATOR FAN MOTOR CAPACITORS 6-16 .............................................

6.17.1 When To Check For A Defective Capacitor 6-16 ...........................................

6.17.2 Removing The Capacitor 6-16 ...........................................................

6.17.3 Checking The Capacitor 6-16 ............................................................

6.18 SUCTION MODULATION VALVE 6-16 .......................................................

6.18.1 Precheck Procedure ............................................................... 6-16

6.18.2 Checking The Stepper valve 6-17 ........................................................

6.18.3 Checking The Drive Module 6-17 ........................................................

6.18.4 Checking The Controller 6-18 ...........................................................

6.18.5 Emergency Repair Procedures: 6-18 .....................................................

6.19 AUTOTRANSFORMER ............................................................... 6-18

6.20 VENT POSITION SENSOR SERVICE 6-19 ..................................................

6.21 CONTROLLER ....................................................................... 6-19

6.21.1 Handling Controller ................................................................ 6-19

6.21.2 Controller Trouble-Shooting 6-19 .........................................................

6.21.3 Controller Programming Procedure 6-20 ..................................................

6.21.4 Removing and Installing the Controller 6-20 ...............................................

6.21.5 Battery Replacement .............................................................. 6-21

6.22 TEMPERATURE SENSOR SERVICE 6-21 ...................................................

6.22.1 Sensor Checkout Procedure 6-21 ........................................................

6.22.2 Sensor Replacement .............................................................. 6-21

6.22.3 Sensor Re--Installation 6-22 .............................................................

6.23 ELECTRONIC PARTLOW TEMPERATURE RECORDER 6-23 ..................................

6.24 MECHANICAL PARTLOW TEMPERATURE RECORDER 6-25 ..................................

6.24.1 Checking The Temperature Recorder 6-25 ................................................

6.25 SAGINOMIYA TEMPERATURE RECORDER 6-27 ............................................

6.26 MAINTENANCE OF PAINTED SURFACES 6-29 ..............................................

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T-285 vi

TABLE OF CONTENTS -- Continued

PARAGRAPH NUMBER Page

6.27 COMPOSITE CONTROL BOX REPAIRS 6-29 ................................................

6.27.1 Introduction ...................................................................... 6-29

6.27.2 Cracks ........................................................................... 6-29

6.27.3 Chips And Holes .................................................................. 6-29

6.27.4 Inserts ........................................................................... 6-29

6.27.5 Door Hinge Inserts ................................................................ 6-29

6.28 COMMUNICATIONS INTERFACE MODULE INSTALLATION 6-32 ..............................

6.29 POWER FACTOR CORRECTOR CAPACITORS (PFC) 6-33 ....................................

ELECTRICAL WIRING SCHEMATIC ............................................................ 7-1

7.1 INTRODUCTION ..................................................................... 7-1

LIST OF ILLUSTRATIONS

FIGURE NUMBER Page

Figure 2-1 Refrigeration Unit -- Front Section 2-1 .....................................................

Figure 2-2 Evaporator Section ................................................................. 2-2

Figure 2-3 Compressor Section ................................................................ 2-3

Figure 2-4 Condenser Section .................................................................. 2-4

Figure 2-5 Water-Cooled Condenser Section 2-5 .....................................................

Figure 2-6 Control Box Section ................................................................. 2-6

Figure 2-7 Refrigeration Circuit Schematic 2-11 .......................................................

Figure 3- 1 Temperature Control System 3-1 ........................................................

Figure 3- 2 Key Pad .......................................................................... 3-2

Figure 3- 3 Display Module .................................................................... 3-2

Figure 3- 4 Micro-Link 2i Controller ............................................................. 3-3

Figure 3- 5 Standard Configuration Report 3-9 .......................................................

Figure 3- 6 Data Reader ....................................................................... 3-10

Figure 4-1 Autotransformer .................................................................... 4-1

Figure 4-2 Make Up Air Flow Chart ............................................................. 4-2

Figure 4-3 Controller Operation -- Perishable Mode 4-5 ...............................................

Figure 4-4 Controller Operation -- Frozen Mode 4-6 ...................................................

Figure 4-5 Perishable Mode Cooling ............................................................ 4-6

Figure 4-6 Perishable Mode Heating ............................................................ 4-7

Figure 4-7 Frozen Mode ....................................................................... 4-7

Figure 4-8 Defrost ............................................................................ 4-8

Figure 6-1 Service Valve ...................................................................... 6-1

Figure 6-2 Manifold Gauge Set ................................................................. 6-1

Figure 6-3 R-134a Manifold Gauge/Hose Set 6-2 .....................................................

Figure 6-4. Refrigeration System Service Connections 6-2 ............................................

Figure 6-5. Compressor Service Connections 6-4 ....................................................

Figure 6-6 Compressor ........................................................................ 6-5

Figure 6-7 Exploded View of Valve Plate 6-6 .........................................................

Figure 6-8 Bottom Plate Removed .............................................................. 6-6

Figure 6-9 Oil Pump and Bearing Head 6-7 ..........................................................

Figure 6-10 Low Profile Oil Pump ............................................................... 6-7

Figure 6-11 Motor End Cover .................................................................. 6-7

Page 14 of 122

vii T-285

LIST OF ILLUSTRATIONS (continued)

FIGURE NUMBER Page

Figure 6-12 Equalizing Tube and Lock Screw Assembly 6-8 ...........................................

Figure 6-13 Crankshaft Assembly .............................................................. 6-8

Figure 6-14 Suction Valve & Positioning Springs 6-8 ..................................................

Figure 6-15 Piston Ring ....................................................................... 6-8

Figure 6-16 High Pressure Switch Testing 6-10 .......................................................

Figure 6-17 Water-Cooled Condenser Cleaning -- Forced Circulation 6-11 ................................

Figure 6-18 Water Cooled Condenser Cleaning - Gravity Circulation 6-12 .................................

Figure 6-19 Thermostatic Expansion Valve Bulb 6-13 ..................................................

Figure 6-20 Hermetic Thermostatic Expansion Valve 6-13 ..............................................

Figure 6-21 Hermetic Thermostatic Expansion Valve Brazing Procedure 6-13 .............................

Figure 6-22. Thermostatic Expansion Valve 6-14 .....................................................

Figure 6-23. Evaporator Fan Assembly 6-15 ..........................................................

Figure 6-24 Suction Modulation Valve (SMV) 6-16 .....................................................

Figure 6-25 Jumper Assembly ................................................................. 6-18

Figure 6-26 Controller Section of the Control Box 6-19 .................................................

Figure 6-27 Sensor Types ..................................................................... 6-21

Figure 6-28 Sensor and Cable Splice 6-22 ...........................................................

Figure 6-29 Supply Sensor Positioning 6-22 ..........................................................

Figure 6-30 Return Sensor Positioning 6-22 ..........................................................

Figure 6-31. Electronic Partlow Temperature Recorder 6-24 ............................................

Figure 6-32. Partlow Mechanical Temperature Recorder 6-27 ...........................................

Figure 6-33. Saginomiya Temperature Recorder 6-28 ..................................................

Figure 6-34 Door Hinge Repair ................................................................. 6-29

Figure 6-35. Insert Location .................................................................... 6-31

Figure 6-36. Communications Interface Installation 6-32 ................................................

Figure 6-37 R-134a Compressor Pressure and Motor Current Curves Versus Ambient Temperature 6-36 .....

Figure 7-1 LEGEND .......................................................................... 7-2

Figure 7-2 SCHEMATIC DIAGRAM -- Normal Evaporator Fan Operation 7-3 ............................

Figure 7-3 SCHEMATIC DIAGRAM -- Single Evaporator Fan Capability 7-4 ..............................

Figure 7-4 SCHEMATIC DIAGRAM -- TransFRESH, Vent Position Sensor (VPS), Humidity & Recorders 7-5

Figure 7-5 WIRING DIAGRAM -- Normal Evaporator Fan Operation,

Units with Dual Capacitor Evaporator Fan Motors 7-6 .....................................

Figure 7-6 WIRING DIAGRAM -- Single Evaporator Fan Capacity ,

Units with Dual Capacitor Evaporator Fan Motors 7-8 .....................................

Figure 7-7 WIRING DIAGRAM -- Normal Evaporator Fan Operation ,

Units with Single Capacitor Evaporator Fan Motors 7-10 ...................................

Figure 7-8 WIRING DIAGRAM -- Single Evaporator Fan Capacity ,

Units with Single Capacitor Evaporator Fan Motors 7-12 ....................................

Figure 7-9 WIRING DIAGRAM -- Electronic Partlow Temperature Recorder 7-14 ..........................

Page 15 of 122

T-285 viii

LIST OF TABLES

TABLE NUMBER Page

Table 2-1 Safety and Protective Devices 2-9 ..........................................................

Table 3-1 Key Pad Function ..................................................................... 3-2

Table 3-2 DataCORDER Configuration Variables 3-8 ..................................................

Table 3-3 DataCORDER Standard Configurations 3-8 ..................................................

Table 3-4 Controller Configuration Variables 3-12 .......................................................

Table 3-5 Controller Function Codes ............................................................ 3-13

Table 3-6 Controller Alarm Indications 3-17 ............................................................

Table 3-7 Controller Pre-Trip Test Codes 3-20 .........................................................

Table 3-8 DataCORDER Function Code Assignments 3-24 ..............................................

Table 3-9 DataCORDER Pre-Trip Result Records 3-25 ..................................................

Table 3-10 DataCORDER Alarm Indications 3-26 .......................................................

Table 6-1 Sensor Temperature/Resistance Chart 6-21 ..................................................

Table 6-2 Temperature-Resistance Chart 6-25 .........................................................

Table 6-3 Crack, Chip & Hole Repair Kit 6-30 ..........................................................

Table 6-4 Insert Repair Kit ...................................................................... 6-30

Table 6-5 Drill Information ...................................................................... 6-30

Table 6-6 Recommended Bolt Torque Values 6-32 ......................................................

Table 6-7 Wear Limits For Compressors 6-34 ..........................................................

Table 6-8 Compressor Torque Values 6-34 ............................................................

Table 6-9 R-134a Temperature - Pressure Chart 6-35 ...................................................

Page 16 of 122

1-1 T-285

SECTION 1

INTRODUCTION

1.1 INTRODUCTION

The Carrier Transicold model 69NT40--511--300 series

units are of lightweight aluminum frame construction,

designed to fit in the front of a container and serve as the

container’s front wall.

They are one piece, self-contained, all electric units

which includes cooling and heating systems to provide

precise temperature control.

The units are suppled with a complete charge of

refrigerant R-134a and compressor lubricating oil and

are ready for operation upon installation. Forklift

pockets are provided for unit installation and removal.

The base unit operates on nominal 380/460 volt, 3

phase, 50/60 hertz power. An optional autotransformer

may be fitted to allow operation on nominal 190/230 , 3

phase, 50/60 hertz power. Power for the control system

is provided by a transformer which steps the supply

power down to 18 and 24 volts, single phase.

The controller is a Carrier Transicold Micro-Link 2i

microprocessor. The controller will operate

automatically to select cooling, holding or heating as

required to maintain the desired set point temperature

within very close limits. The unit may also be equipped

with a mechanical or electronic temperature recorder.

The controller has a keypad and display for viewing or

changing operating parameters. The display is also

equipped with lights to indicate various modes of

operation.

1.2 CONFIGURATION IDENTIFICATION

Unit identification information is provided on a plate

located near the compressor. The plate provides the

unit model number, the unit serial number and the unit

parts identification number (PID). The model number

identifies the overall unit configuration while the PID

provides information on specific optional equipment,

factory provision to allow for field installation of optional

equipment and differences in detailed parts.

Configuration identification for the models covered

herein are provided in the Carrier Transicold Container

Identification Matrix found at the Carrier Web site,

www.container.carrier.com.

1.3 OPTION DESCRIPTION

Various options may be factory or field equipped to the

base unit. These options are listed in the tables and

described in the following subparagraphs.

1.3.1 Battery

The refrigeration controller may be fitted with standard

replaceable batteries or a rechargeable battery pack.

1.3.2 Dehumidification

The unit may be fitted with a humidity sensor. This

sensor allows setting of a humidity set point in the

controller. In the dehumidification mode the controller

will operate to reduce internal container moisture level.

1.3.3 Control Box

The control box may be of aluminum or composite

material and each type box may be fitted with a lockable

door.

1.3.4 Temperature Readout

The unit may be fitted with suction and discharge

temperature sensors. The sensor readings may be

viewed on the controller display.

1.3.5 Pressure Readout

The unit may be fitted with suction and discharge

pressure gauges or suction and discharge transducers

or no pressure readout. The transducer readings may

be viewed on the controller display.

1.3.6 USDA

The unit may be supplied with fittings for additional

temperature probes which allow recording of USDA

Cold Treatment data by the integral DataCORDER

function of the Micro--Link refrigeration controller.

1.3.7 Interrogator

Units that use the DataCORDER function are fitted with

interrogator receptacles for connection of equipment to

download the recorded data. Two receptacles may be

fitted, one accessible from the front of the container and

the other mounted inside the container (with the USDA

receptacles).

1.3.8 Remote Monitoring

The unit may be fitted with a remote monitoring

receptacle. This item allows connection of remote

indicators for COOL, DEFROST and IN RANGE.

Unless otherwise indicated, the receptacle is mounted

at the control box location

1.3.9 Communications.

The unit may be fitted with a communications interface

module. The communications interface module is a

slave module which allows communication with a

master central monitoring station. The module will

respond to communication and return information over

the main power line. Refer to the ship master system

technical manual for further information.

1.3.10 Compressor

The unit is fitted with a single speed reciprocating

compressor.

Page 17 of 122

1-2 T-285

1.3.11 Condenser Coil

The unit may be fitted with a 2 row or 4 row coil using

nominal 3/8 inch tubing, or the unit may be fitted with a 3

row coil using 7mm tubing. The required refrigerant

charge is different for each coil.

1.3.12 Autotransformer

An autotransformer may be provided to allow operation

on 190/230, 3phase, 50/60 hertz power. The

autotransformer raises the supply voltage to the

nominal 380/460 volt power required by the base unit.

The autotransformer may also be fitted with an

individual circuit breaker for the 230 volt power.

If the unit is equipped with an autotransformer and

communications module, the autotransformer will be

fitted with a transformer bridge unit (TBU) to assist in

communications.

1.3.13 Temperature Recorder

One of three recording devices may be fitted to the unit.

The devices include a mechanical recorder

manufactured by Partlow Corporation, a mechanical

recorder manufactured by Saginomiya Corporation,

and an electronic recorder manufactured by Partlow

Corporation.

1.3.14 Gutters

Rain gutters may be fitted over the control box and

recorder section to divert rain away form the controls.

The different gutters include standard length bolted

gutters, extended length gutters and riveted gutters.

1.3.15 Handles

The unit may be equipped with handles to facilitate

access to stacked containers. These handles may

include fixed handles (located at the sides of the unit)

and/or a hinged handle at the center (attached to the

condenser coil cover).

1.3.16 Thermometer Port

The unit may be fitted with ports in the front of the frame

for insertion of a thermometer to measure supply and/or

return air temperature. If fitted, the port(s) will require a

cap and chain.

1.3.17 Water Cooling

The refrigeration system may be fitted with a water

cooled condenser. The condenser is constructed using

copper--nickel tube for sea water applications. The

water cooled condenser is in series with the air cooled

condenser and replaces the standard unit receiver.

When operating on the water cooled condenser, the

condenser fan is deactivated by either a water pressure

switch or condenser fan switch.

1.3.18 Back Panels

Back panel designs that may be fitted include panels of

aluminum and stainless steel. Panels may have access

doors and/or hinge mounting.

1.3.19 460 Volt Cable

Various power cable and plug designs are available for

the main 460 volt supply. The plug options tailor the

cables to each customers requirements.

1.3.20 230 Volt Cable

Units equipped with an autotransformer require an

additional power cable for connection to the 230 volt

source. Various power cable and plug designs are

available. The plug options tailor the cables to each

customers requirements.

1.3.21 Cable Restraint

Various designs are available for storage of the power

cables. These options are variations of the compressor

section front cover.

1.3.22 Upper Air (Fresh Air Make Up)

The unit may be fitted with an upper fresh air makeup

assembly. The fresh air makeup assembly is available

with a Vent Positioning Sensor (VPS) and may also be

fitted with screens.

1.3.23 Lower Air (Fresh Air Make Up)

The unit may be fitted with a lower fresh air makeup

assembly. These assemblies are supplied in two

designs, the standard design and themacro design. The

openings may also be fitted with screens.

1.3.24 Controlled Atmosphere

The units may be fitted with the TransFresh option.

For information on the TransFresh system, contact

TransFresh Corporation, P.O. Box 1788, Salinas CA

93902

1.3.25 Arctic Mode

To improve operation in cold ambients, the unit may be

fitted with a crankcase heater and/or a condensate drain

line heater. The crankcase heater is operated, before

start--up, to warm the compressor oil and boil off any

liquid refrigerant that may be present in the crankcase.

The drain line heater is operated to prevent freezing of

the evaporator condensate drain system.

1.3.26 Humidification

The unit may be equipped with the Carrier Transicold

NatureFresh humidity management system. The

system includes a water tank, water pump, water heater

and atomizer along with various control and monitoring

devices. It is designed to add additional moisture into

the supply air for control of cargo moisture level. A

separately bound manual covering operation and parts

for the CTD NatureFresh System is available, see the

following chart.

Manual

Number

Equipment

Covered

Type of

Manual

T-297 Humidity Management

System Option

Technical

Supplement

1.3.27 Power Correction

The unit may be fitted with a set of power factor

correction capacitors to assist in correction of

imbalance in current draw by the compressor.

1.3.28 Evaporator

Evaporator section options include a semi--hermetic

thermal expansion valve, a hermetic thermal expansion

Page 18 of 122

1-3 T-285

valve and two sizes of heat exchangers. The unit may

have 4 or 6 heaters.

1.3.29 Evaporator Fan Operation

Two evaporator fan motor operation systems are

available. On units with Normal Evaporator Fan

Operation, opening of an evaporator fan internal

protector will shut down the unit. On units equipped with

Single Evaporator Fan Capability, additional relays are

installed to allow the unit to continue to operate on a

single fan.

1.3.30 Labels

Operating Instruction and Function Code listing labels

will differ depending on the options installed. For

example, additional operating instructions are required

to describe start--up of a unit equipped with an

autotransformer. Where the labels are available with

additional languages, they are listed in the parts list.

1.3.31 Plate Set

Each unit is equipped with a tethered set of wiring

schematic and wiring diagram plates. The plate sets are

ordered using a seven digit base part number and a two

digit dash number. See the unit identification Matrix

found at the Carrier Web site,

www.container.carrier.com.

1.3.32 Controller

Two different controllers are available:

1. Remanufactured -- Controller is the equivalent of a

new OEM controller and is supplied with a 12 month

warranty.

2. Repaired -- Controller has had previous faults

repaired and upgraded with the latest software.

Note: Repaired controllers are NOT to be used for

warranty repairs only full OEM Remanufactured

controllers are to be used.

Controllers will be factory equipped with the latest

version of operational software, but will NOT be

configured for a specific model number and will need to

be configured, at the time of installation or sale.

The following Part numbers cover ALL previous

MicroLink 2 and 2i controllers:

Part Number

Model

Reman- ufactured Repaired Description Model

Usage

N/A 12--56000 ML2 Recip

(SWR12XX)

69NT40--489

/ 501

12--55001 12--56001 ML2I Recip.

(SWR12XX)

69NT40--489

/ 501

12--55002 12--56002 ML2I Recip.

(SWR51XX) 69NT40--511

12--55003 12--56003 ML2I Scroll

(SWR53XX) 69NT40--531

12--55004 12--56004 DataCorder

(SWR21XX)

69NT40--489

/ 501

12--55005 12--56005 CA

(SWR31XX)

69NT40--489

--1XX

The identification label on each controller will have the

part number as shown above followed by a dash and

then a blank space to allow the final dash number to be

added at the time of sale.

Once a unit has been configured, the last digits of the

part number can be found in the T--300 Unit Matrix. It is

important when installing a controller that this final piece

of the part number is added.

Example -- If a repaired controller is required for a

69NT40--511--343, PID NT0809:

Use the ML2I reciprocating compressor base controller

12--56002. The dash number from the T--300 Unit

Matrix (Controller Column) is 90.

The full part number for the necessary controller is

12--56002--90.

1.3.33 Condenser Grille

Two styles of condenser grilles are available, direct

bolted grilles and hinged grilles.

1.3.34 Emergency Bypass

The unit may be equipped with switches to allow

emergency bypass of the controller. The EMERGENCY

BYPASS switch functions to bypass the controller in the

event of controller failure. The EMERGENCY

DEFROST switch functions to bypass all controls and

place the unit in the defrost mode.

Page 19 of 122

2-1 T-285

SECTION 2

DESCRIPTION

2.1 GENERAL DESCRIPTION

2.1.1 Refrigeration Unit -- Front Section

The unit is designed so that the majority of the

components are accessible from the front, see

Figure 2-1. The upper access panels allow entry into the

evaporator section, and the center access panel allows

access to the thermostatic expansion valve and

evaporator coil heaters. The unit model number, serial

number and parts identification number can be found on

the serial plate to the left of the compressor.

2.1.2 Fresh Air Makeup Vent

The function of the upper or lower makeup air vent is to

provide ventilation for commodities that require fresh air

circulation.

4 9

1. Access Panel (Evap. Fan #1)

2. Access Panel (Heater & Thermostatic

Expansion Valve)

3. Fork Lift Pockets

4. Control Box

5. Compressor

6. Unit Serial Number, Model Number and

Parts Identification Number (PID) Plate

7. Condenser Fan

8. TransFRESH Communications Connector

9. Interrogator Connector (Front right)

10. Temperature Recorder

11. Lower Fresh Air Makeup Vent Location

(Blank Cover Shown)

12. TIR (Transports Internationaux Routiers)

Sealing Provisions - Typical All Panels

13. Upper Fresh Air Makeup Vent (with VPS if

equipped)

14. Access Panel (Evap. Fan #2)

Figure 2-1 Refrigeration Unit -- Front Section

Page 20 of 122

T-285 2-2

2.1.3 Evaporator Section

The evaporator section (Figure 2-2) contains the

temperature recorder bulb or return recorder sensor,

return temperature sensor, thermostatic expansion

valve, dual-speed evaporator fans (EM1 and EM2),

evaporator coil and heater, drain pan heater, defrost

heaters, defrost temperature sensor, heat termination

thermostat, and heat exchanger.

The evaporator fans circulate air through the container

by pulling it in the top of the unit, directing it through the

evaporator coil, where it is heated or cooled, and

discharging it at the bottom.

The evaporator components are accessible by

removing the upper rear panel (as shown in the

illustration) or by removing the front access panels.

ALTERNATE USDA

LOCATION

HTT Alternate Location

1. Evaporator Fan Motor #1

2. Return Recorder Sensor

3. Return Temperature Sensor

4. Humidity Sensor

5. Mechanical Recorder Bulb

6. Evaporator Fan Motor #2

7. Defrost Temperature Sensor

8. Heater Termination Thermostat

9. Evaporator Coil

10. Drain Pan Heater

11. Hermetic Thermostatic Expansion Valve

12. Semi--Hermetic Thermostatic Expansion Valve

13. Heat Exchanger

14. Interrogator Connector (Rear)

15. USDA Probe Receptacle PR2

16. USDA Probe Receptacle PR1

17. USDA Probe Receptacle PR3

18. Cargo Probe Receptacle PR4

19. Evaporator Coil Heaters

Figure 2-2 Evaporator Section

Page 21 of 122

2-3 T-285

2.1.4 Compressor Section

The compressor section includes the compressor (with

high pressure switch), power cable storage

compartment, and autotransformer.

This section also contains the suction modulating valve,

modulating valve stepper motor drive, discharge

pressure regulator valve and discharge/suction

pressure transducers.

The supply temperature sensor, supply recorder sensor

and ambient sensor are located at the right side of the

compressor.

1. Autotransformer

2. Power Cables and Plug

3. Compressor Sight Glass View Port

4. Compressor Guard

5. Supply Temperature Sensor

6. Supply Recorder Sensor

7. Ambient Sensor

8 Supply Air Thermometer Port

9. Discharge Service Valve

10. Discharge Temperature Sensor

11. Discharge Pressure Regulator Valve

12. Suction Temperature Sensor

13. Quench Valve Temperature Bulb

14. Stepper Motor Drive (for item 18)

15. Emergency Bypass Module (for item 18)

16. Quench Valve

17. Access Valve

18. Suction Modulating Valve

19. Suction Service Valve

20. Compressor Crankcase Heater

21. Compressor Motor

22. Suction Pressure Transducer

23. High Pressure Switch

24. Discharge Pressure Transducer

Figure 2-3 Compressor Section

Page 22 of 122

T-285 2-4

2.1.5 Air Cooled Condenser Section

The air cooled condenser section (Figure 2-4) consists

of the condenser fan, condenser coil, receiver with sight

glass/moisture indicator, quench valve, manual liquid

line valve, filter-drier, condenser pressure transducer

and fusible plug.

The condenser fan pulls air in the bottom of the coil and it

is discharged horizontally out through the condenser fan

grille.

2 4 3

1. Grille and Venturi Assembly

2. Condenser Fan

3. Key

4. Condenser Fan Motor

5. Condenser Coil Cover

6. Condenser Coil

7. Condenser Motor Mounting Bracket

8. Receiver

9. Sight Glass

10. Fusible Plug (Rupture Disc -- Alternate)

11. Condenser Pressure Transducer

12. Sight Glass/Moisture Indicator

13. Filter-Drier

14. Liquid Line Service Valve

15. Quench Valve

Figure 2-4 Condenser Section

Page 23 of 122

2-5 T-285

2.1.6 Water-Cooled Condenser Section

The water-cooled condenser section (Figure 2-5)

consists of a water-cooled condenser, sight glass,

quench expansion valve, rupture disc, condenser

pressure transducer, filter-drier, water couplings and

water pressure switch. The water cooled condenser

replaces the standard unit receiver.

34 5 6

11 10

1. Sight Glass

2. Water-Cooled Condenser

3. Rupture Disc

4. Condenser Pressure Transducer

5. Quench Valve

6. Filter-Drier

7. Liquid Line Service Valve

8. Moisture/Liquid Indicator

9. Coupling (Water In)

10. Self Draining Coupling (Water Out)

11. Water Pressure Switch

Figure 2-5 Water-Cooled Condenser Section

Page 24 of 122

T-285 2-6

2.1.7 Control Box Section

The control box (Figure 2-6) includes the manual

operation switches; circuit breaker (CB-1); compressor,

fan and heater contactors; control power transformer;

fuses; key pad; display module; current sensor module;

controller module and the communications interface

module.

2.1.8 Communications Interface Module

The communications interface module is a slave

module which allow communication with a master

central monitoring station. The module will respond to

communication and return information over the main

power line. Refer to the master system technicalmanual

for further information.

21 15 20 19 18 17

1 2 3 4 5 6

24 23 22 16 14 8 13 12 11 10 9 7

1. Compressor Contactor

2. Heater Contactor

3. Display Module

4. Communications Interface Module

5. Controller/DataCORDER Module (Controller)

6. Key Pad

7. Emergency Defrost Light

8. Start-Stop Switch

9. Remote Monitoring Receptacle

10. Manual Defrost Switch (if equipped)

11. Condenser Fan Switch

12. Emergency Defrost Switch

13. Emergency Defrost Fuse

14. Emergency Bypass Switch

15. Controller Battery Pack

16. Interrogator Connector (Box Location)

17. Control Transformer

18. Evaporator Fan Contactor - E1

19. Evaporator Fan Contactor - S1

20. Evaporator Fan Contactor - S2 or EF

21. Evaporator Fan Contactor - E2 or ES

22. Condenser Fan Contactor

23. Circuit Breaker -- 460V

24. Current Sensor Module

Figure 2-6 Control Box Section

Page 25 of 122

2-7 T-285

2.2 REFRIGERATION SYSTEM DATA

Number of Cylinders 6

Model 06DR

CFM 41

a Compressor/Motor Weight (Dry) 118 kg (260 lb) a. Compressor/Motor

Assembly Assembly Approved Oil Mobil ST32

Oil Charge 3.6 liters (7.6 U.S. pints)

Oil Sight Glass

The oil level range, with the compressor off,

should be between the bottom and one-eighth

level of the sight glass.

b. Expansion Valve Superheat

Verify at --18 _C

(0 _F) container box

temperature

4.5 to 6.7 _C (8 to 12 _F)

c Heater Termination Thermostat Opens 54 (¦ 3) _C = 130 (¦ 5) _F

c. Heater Termination Thermostat Closes 38 (¦ 4) _C = 100 (¦ 7) _F

d High Pressure Switch

Cutout 25 (¦ 1.0) kg/cm@ = 350 (¦ 10) psig d. High Pressure Switch Cut-In 18 (¦ 0.7) kg/cm@ = 250 (¦ 10) psig

Charge Requirements -- R-134a

Unit Configuration 2 row

condenser

3 row

condenser

4 row

condenser

e. Refrigerant Charge Water-Cooled

Condenser

4.5 kg

(9.0 lbs)

4.9 kg

(10.75 lbs)

5.2 kg

(11.5 lbs)

Receiver 3.7 kg

(8.3 lbs)

4.0 kg

(8.8 lbs)

4.9 kg

(10.8 lbs)

NOTE

When replacing the following componen g components (f.), (g.) and (h.) , refer to the installation instructions included with

the replacement part for additional information.

f Fusible Plug* Melting point 99 _C = (210 _F) f. Fusible Plug* Torque* 6.2 to 6.9 mkg (45 to 50 ft-lbs)

g. Sight Glass/Moisture Indicator Torque 8.9 to 9.7 mkg (65 to 70 ft-lbs)

Bursts at 35 ¦ 5% kg/cm@ = (500 ¦ 5% psig)

h. Rupture Disc Torque

(P/N 14-00215-03) 1.4 to 2 mkg (10 to 15 ft-lbs)

i. Condenser Pressure

Condenser Fan Starts

The condenser fan will start if the condenser

pressure is greater than 14.06 kg/cm@ (200

psig) OR the condenser fan is OFF for more

than 60 seconds. i. Condenser Pressure

Transducer

Condenser Fan Stops

The condenser fan will stop if the condenser

pressure is less than 9.14 kg/cm@ (130 psig)

AND the condenser fan remains ON for at least

30 seconds.

j. Unit Weight Refer to unit model number plate.

k Water Pressure Switch

Cut-In 0.5 ¦ 0.2 kg/cm@ (7 ¦ 3 psig) k. Water Pressure Switch Cutout 1.6 ¦ 0.4 kg/cm@ (22 ¦ 5 psig)

l. Discharge Pressure Regulator Factory Setting 32.7 ¦ 2.5 kg/cm@ (72¦ 5.5 psig)

* Rupture Disc, part number 14--00215--04 may be installed as an alternate for the receiver mounted fusible plug.

Page 26 of 122

T-285 2-8

2.3 ELECTRICAL DATA

CB-1 Trips at 29 amps

a. Circuit Breaker a. Circuit Breaker CB-2 (50 amp) Trips at 62.5 amps

CB-2 (70 amp) Trips at 87.5 amps

b. Compressor

Motor Full Load Amps (FLA) 17.6 amps @ 460 vac

(with current limiting set at 21 amps)

380 vac, Single Phase,

50 hz

460 vac, Single Phase,

60 hz

c. Condenser Fan Full Load Amps 1.3 amps 1.6 amps c. Condenser Fan

Motor Horsepower 0.43 hp 0.75 hp

Rotations Per Minute 1425 rpm 1725 rpm

Voltage and Frequency 360 -- 460 vac ¦ 2.5 hz 400 -- 500 vac ¦ 2.5 hz

Bearing Lubrication Factory lubricated, additional grease not required.

Rotation Counter-clockwise when viewed from shaft end.

Number of Heaters 0 or 1

d Drain Pan Heaters Rating 750 watts +5 /--10 % @ 460 vac d. Drain Pan Heaters Resistance (cold) 285 ¦ 7.5% ohms @ 20 _C (68 _F)

Type Sheath

Number of Heaters 4 or 6

e. Evaporator Coil Rating 750 watts +5/--10% each @ 230 vac e. Evaporator Coil

Heaters Resistance (cold) 66.8 to 77.2 ohms @ 20 _C (68 _F)

Type Sheath

380 vac/50 hz 460 vac/60 hz

Full Load Amps

High Speed 1.6 2.0

Full Load Amps

Low Speed 0.8 1.0

Nominal Horsepower

High Speed 0.70 0.84

f. Evaporator Fan

Nominal Horsepower

Low Speed 0.09 0.11

f. Evaporator Fan

Motor(s) Rotations Per Minute

High Speed 2850 rpm 3450 rpm

Rotations Per Minute

Low Speed 1425 rpm 1750 rpm

Voltage and Frequency 360 -- 460 vac ± 1.25 hz 400 -- 500 vac ± 1.5 hz

Voltage & Frequency us- ing power autotransformer 180 -- 230 vac ± 1.25hz 200 -- 250 vac ± 1.5 hz

Bearing Lubrication Factory lubricated, additional grease not required

Rotation CW when viewed from shaft end

Control Circuit 10 amps (F3)

Controller/DataCORDER 5 amps (F1 & F2)

g Fuses Emergency Defrost 5 amps (FED) g. Fuses

Drain Line Heater 5 amps (FDH)

Humidity Power

Transformer 5 amps (FH)

h. Compressor Crankcase Heater 180 watts @ 460 vac

Page 27 of 122

2-9 T-285

Orange wire Power

Red wire Output

Brown wire Ground

Input voltage 5 vdc

i Humidity Sensor Output voltage 0 to 3.3 vdc

i. Humidity Sensor Output voltage readings verses relative humidity (RH) percentage:

30% 0.99 V

50% 1.65 V

70% 2.31 V

90% 2.97 V

j. Controller Setpoint Range --30 to +30 _C (--22 to +86 _F)

2.4 SAFETY AND PROTECTIVE DEVICES

Unit components are protected from damage by safety

and protective devices listed in the following table.

These devices monitor the unit operating conditions and

open a set of electrical contacts when an unsafe

condition occurs.

Open safety switch contacts on either or both of devices

IP-CP or HPS will shut down the compressor.

Open safety switch contacts on device IP-CM will shut

down the condenser fan motor.

The entire refrigeration unit will shut down if one of the

following safety devices open: (a) Circuit Breaker(s); (b)

Fuse (F3/15A); or (c) Evaporator Fan Motor Internal

Protector(s) -- (IP-EM).

Table 2-1 Safety and Protective Devices

UNSAFE CONDITION SAFETY DEVICE DEVICE SETTING

Circuit Breaker (CB-1) -- Manual Reset Trips at 29 amps (460 vac)

Excessive current draw Circuit Breaker (CB-2, 50 amp) --Manual Reset Trips at 62.5 amps (230 vac)

Circuit Breaker (CB-2, 70 amp) --Manual Reset Trips at 87.5 amps (230 vac)

Excessive current draw in the

control circuit Fuse (F3) 10 amp rating

Excessive current draw by the

controller Fuse (F1 & F2) 5 amp rating

Excessive current draw by the

emergency defrost circuit Fuse (FED) 5 amp rating

Excessive condenser fan mo- tor winding temperature Internal Protector (IP-CM) -- Automatic Reset N/A

Excessive compressor motor

winding temperature Internal Protector (IP-CP) -- Automatic Reset N/A

Excessive evaporator fan mo- tor(s) winding temperature Internal Protector(s) (IP-EM) -- Automatic Reset N/A

Abnormal pressures/tempera- tures in the high refrigerant

side

Fusible Plug -- Used on the Receiver

Rupture Disc -- Used on the Water-Cooled Con- denser

99 _C = (210 _F)

35 kg/cm@ = (500 psig)

Abnormally high discharge

pressure High Pressure Switch (HPS) Opens at 25 kg/cm@

(350 psig)

Page 28 of 122

T-285 2-10

2.5 REFRIGERATION CIRCUIT

Starting at the compressor, (see Figure 2-7 upper

schematic) the suction gas is compressed to a higher

pressure and temperature.

The gas flows through the discharge service valve into

the pressure regulator valve. During periods of low

ambient operation, the pressure regulator valve

modulates the flow of refrigerant to maintain a pre set

minimum discharge pressure. Refrigerant gas then

moves into the air-cooled condenser. When operating

with the air-cooled condenser active, air flowing across

the coil fins and tubes cools the gas to saturation

temperature. By removing latent heat, the gas

condenses to a high pressure/high temperature liquid

and flows to the receiver which stores the additional

charge necessary for low temperature operation.

When operating with the water cooled condenser active

(see Figure 2-7, lower schematic), the refrigerant gas

passes through the air cooled condenser and enters the

water cooled condenser shell. The water flowing inside

the tubing cools the gas to saturation temperature in the

same manner as the air passing over the air cooled

condenser. The refrigerant condenses on the outside of

the tubes and exits as a high temperature liquid. The

water cooled condenser also acts as a receiver, storing

excess refrigerant.

The liquid refrigerant continues through the liquid line

service valve, the filter-drier (which keeps refrigerant

clean and dry), and a heat exchanger (that increases

subcooling of the liquid) to the thermostatic expansion

valve. As the liquid refrigerant passes through the

variable orifice of the expansion valve, some of it

vaporizes into a gas (flash gas). Heat is absorbed from

the return air by the balance of the liquid, causing it to

vaporize in the evaporator coil. The vapor then flows

through the suction modulating valve to the compressor.

The thermostatic expansion valve is activated by the

bulb strapped to the suction line near the evaporator

outlet. The valve maintains a constant superheat at the

coil outlet regardless of load conditions.

During periods of low load, the suction modulating valve

decreases flow of refrigerant to the compressor. This

action balances the compressor capacity with the load

and prevents operation with low coil temperatures. In

this mode of operation, the quench valve will open as

required to provide sufficient liquid refrigerant flow into

the suction line for cooling of the compressor motor. The

quench valve senses refrigerant condition entering the

compressor and modulates the flow to prevent entrance

of liquid into the compressor.

The refrigeration system is also fitted with a condenser

pressure transducer which feeds information to the

controller. When operating on the air cooled condenser,

the controller programming will operate the condenser

fan so as to attempt to maintain discharge pressures

above 130 psig in low ambients. At ambients below

27_C (80_F), the condenser fan will cycle on and off

depending on condenser pressure and operating times.

1 The condenser fan will start if the condenser pres- sure is greater than 200 psig OR the condenser fan

has been OFF for more than 60 seconds.

2 The condenser fan will stop if the condenser pres- sure is less than 130 psig AND the condenser fan

has been running for at least 30 seconds.

At ambients above 27_C (80_F), condenser pressure

control is disabled and the condenser fan runs

continuously.

On systems fitted with a water pressure switch, the

condenser fan will be off when there is sufficient

pressure to open the switch. If water pressure drops

below the switch cut out setting, the condenser fan will

be automatically started. When operating a system

fitted with a condenser fan switch, the condenser fan will

be off when the switch is placed in the “O” position. The

condenser fan will be on when the switch is placed in the

“I” position.

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Page 29 of 122

2-11 T-285

FILTER DRIER

TXV

TXV BULB

MODULATING VALVE

PRESSURE

TRANSDUCER

HEAT EXCHANGER

SIGHT GLASS

FILTER DRIER

HEAT EXCHANGER

MODULATING VALVE

PRESSURE

TRANSDUCER

SIGHT GLASS

FUSIBLE PLUG

RECEIVER

SERVICE VALVE

WATER-COOLED

CONDENSER

PRESSURE REGULATOR

TXV

TXV BULB

EVAPORATOR

CONDENSER

PRESSURE TRANSDUCER

SERVICE VALVE

PRESSURE REGULATOR

EVAPORATOR

CONDENSER

SERVICE VALVE

Circuit with Receiver

QUENCH VALVE

Circuit with Water Cooled Condenser

FUSIBLE PLUG

Discharge

Liquid

Suction

Legend

Figure 2-7 Refrigeration Circuit Schematic

Page 30 of 122

3-1 T-285

SECTION 3

MICROPROCESSOR

3.1 TEMPERATURE CONTROL MICROPRO- CESSOR SYSTEM

The temperature control Micro-Link 2i microprocessor

system (see Figure 3- 1) consists of a key pad, display

module, control module (controller) and interconnecting

wiring. The controller houses the temperature control

software and the DataCORDER Software. The

temperature control software functions to operate the

unit components as required to provide the desired

cargo temperature and humidity. The DataCORDER

software functions to record unit operating parameters

and cargo temperature parameters for future retrieval.

Coverage of the temperature control software begins

with paragraph 3.2. Coverage of the DataCORDER

software is provided in paragraph 3.6.

The key pad and display module serve to provide user

access and readouts for both of the controller functions,

temperature control and DataCORDER. The functions

are accessed by key pad selections and viewed on the

display module. The components are designed to

permit ease of installation and removal.

DISPLAY

CONTROL MODULE DISPLAY MODULE

KEY PAD

CONFIGURATION

SOFTWARE

CONFIGURATION

VARIABLE

(CnF##)

TEMPERATURE CONTROL SOFTWARE

ALARMS

(AL<70)

PRE--TRIP

INTERROGATION

CONNECTOR

DATAREADER

Computer Device

With DataLine

Software

DataCORDER SOFTWARE

OPERATIONAL

SOFTWARE

FUNCTION

CODE (Cd)

DISPLAY

CONFIGURATION

SOFTWARE

CONFIGURATION

VARIABLE

(dCF## read only)

ALARMS

(AL>69)

DATA

STORAGE

MEMORY

OPERATIONAL

SOFTWARE

FUNCTION

CODE (dC)

DISPLAY

(Scrollback)

Figure 3- 1 Temperature Control System

Page 31 of 122

T-285 3-2

3.1.1 Key Pad

The key pad (Figure 3- 2) is mounted on the right-hand

side of the control box. The key pad consists of eleven

push button switches that act as the user’s interface

with the controller. Descriptions of the switch functions

are provided in Table 3-1.

ENTER

BATTERY

POWER

MANUAL

DEFROST/

INTERVAL

CODE

SELECT

PRE

TRIP

ALARM

LIST

ALT.

MODE

RETURN

SUPPLY

Figure 3- 2 Key Pad

COOL HEAT DEFROSTIN RANGEALARM SUPPLY RETURN

SETPOINT/Code AIR TEMPERATURE/Data

Figure 3- 3 Display Module

3.1.2 Display Module

The display module (Figure 3- 3) consists of five digit

displays and seven indicator lights. The indicator lights

include:

1. Cool -- White LED: Energized when the refrigerant

compressor is energized.

2. Heat -- Orange LED: Energized to indicate heater op- eration in the heat or defrost mode.

3. Defrost -- Orange LED: Energized when the unit is in

the defrost mode.

4. In-Range -- Green LED: Energized when the con- trolled temperature probe is within specifiedtolerance

of set point.

NOTE

The controlling probe in the perishable range is

the SUPPLY air probe and the controlling probe

in the frozen range is the RETURN air probe.

Table 3-1 Key Pad Function

KEY FUNCTION

Code Select Accesses function codes.

Pre-Trip Displays the pre-trip selection menu.

Discontinues pre-trip in progress.

Alarm List Displays alarm list and clears the

alarm queue .

Manual

Defrost/

Interval

Displays selected defrost mode. De- pressing and holding the Defrost in- terval key for five (5) seconds will ini- tiate defrost using the same logic as

if the optional manual defrost switch

was toggled on.

The Manual Defrost function can also

be selected by simultaneously press- ing and holding the Pre--Trip and Alt.

Mode buttons.

Enter Confirms a selection or saves a

selection to the controller

Arrow Up Change or scroll a selection upward

Pre-trip advance or test interruption.

Arrow Down Change or scroll a selection down- ward. Pre-trip repeat backward

Return/

Supply

Displays non-controlling probe tem- perature (momentary display).

_C/_F

Displays alternate English/Metric

scale (momentary display). When set

to _F, pressure is displayed in psig

and vacuum in “/hg. “P” appears after

the value to indicate psig and “i” ap- pears for inches of mercury.

When set to _C. pressure readings

are in bars. “b” appears after the val- ue to indicate bars.

Battery

Power

Initiate battery backup mode to allow

set point and function code selection

if AC power is not connected.

ALT. Mode

This key is pressed to switch the

functions from the temperature soft- ware to the DataCORDER Software.

The remaining keys function the

same as described above except the

readings or changes are made to the

DataCORDER programming.

5. Supply -- Yellow LED: Energized when the supply air

probe is used for control. When this LED is illuminated,

the temperature displayed in the AIR TEMPERATURE

display is the reading at the supply air probe. This LED

will flash if dehumidification or humidification is en- abled.

6. Return -- Yellow LED: Energized when the return air

probe is used for control. When this LED is illuminated,

the temperature displayed in the AIR TEMPERATURE

display is the reading at the return air probe. This LED

will flash if dehumidification or humidification is en- abled.

7. Alarm -- Red LED: Energized when there is an active

or an inactive shutdown alarm in the alarm queue.

Page 32 of 122

3-3 T-285

1 2 33 3 3 3 4 5 67 8

1. Mounting Screw

2. Micro-Link 2i

Controller

3. Connectors

4. Test Points

5. Fuses

6. Control Circuit Power Connection

(Location: In back of controller)

7. Software Programming Port

8. Battery Pack

Figure 3- 4 Micro-Link 2i Controller

3.1.3 Controller

CAUTION

Do not remove wire harnesses from con- troller unless you are grounded to the unit

frame with a static safe wrist strap.

CAUTION

Unplug all controller wire harness connec- tors before performing arc welding on any

part of the container.

NOTE

Do not attempt to service the controller. Break- ing the seal will void the warranty.

The Micro--Link 2i controller is a single module

microprocessor as shown in Figure 3- 4. It is fitted with

test points, harness connectors and a software card

programming port.

3.2 CONTROLLER SOFTWARE

The controller software is a custom designed program

that is subdivided into the Configuration Software and

the Operational Software. The controller software

performs the following functions:

a. Control supply or return air temperature to required

limits, provide modulated refrigeration control, elec- tric heat control and defrost. Defrost is performed to

clear build up of frost and ice from the coil to ensure

continuous conditioned air delivery to the load.

b. Provide default independent readouts of set point and

supply or return air temperatures.

c. Provide ability to read and (if applicable) modify the

Configuration Software Variables, Operating Soft- ware Function Codes and Alarm Code Indications.

d. Provide a Pre-Trip step-by-step checkout of refrigera- tion unit performance including: proper component

operation, electronic and refrigeration control opera- tion, heater operation, probe calibration, pressure

limiting and current limiting settings.

e. Provide battery powered ability to access or change

selected codes and set point without AC power con- nected

f. Provide the ability to reprogram the software through

the use of a memory card. The memory card auto- matically downloads new software to the controller

when inserted.

3.2.1 Configuration Software (Configuration

Variables)

The Configuration Software is a variable listing of the

components available for use by the Operational

Software. This software is factory installed in

accordance with the equipment fitted and options listed

on the original purchase order. Changes to the

Configuration Software are required only when the

original software has been lost or a physical change has

been made to the unit such as the addition or removal of

an option. A Configuration Variable list is provided in

Table 3-4 . Change to the factory installed Configuration

Software is achieved via a configuration card.

3.2.2 Operational Software (Function Codes)

The Operational Software is the actual operation

programming of the controller which activates or

deactivates components in accordance with current unit

operation conditions and operator selected modes of

operation.

The programming is divided into function codes. Some

of the codes are read only while the remaining codes

may be user configured. The value of the user

configurable codes can be assigned in accordance with

user desired mode of operation. A list of the function

codes is provided in Table 3-5 .

To access the function codes, perform the following:

a. Press the CODE SELECT key, then press an arrow

key until the left window displays the desired code

number.

b. The right window will display the value of this item for

five seconds before returning to the normal display

mode.

c. If a longer time is desired, press the ENTER key to

extend the time to 30 seconds.

3.3 MODES OF OPERATION

The Operational Software responds to various inputs.

These inputs come from the temperature and pressure

sensors, the temperature set point, the settings of the

the configuration variables and the function code

assignments. The action taken by the Operational

Page 33 of 122

T-285 3-4

Software will change if any one of the inputs changes.

Overall interaction of the inputs is described as a “mode”

of operation. The modes of operation include,

perishable (chill) mode and frozen mode. Descriptions

of the controller interaction and modes of operation are

provided in the following sub paragraphs.

3.3.1 Temperature Control -- Perishable Mode

With configuration variable CnF26 (Heat Lockout

Temperature) set to --10_C the perishable mode of

operation is active with set points above --10_C (+14_F).

With the variable set to --5_C, the perishable mode is

active below --5_C (+23_F). Refer to Table 3-4.

When in the perishable mode the controller maintains

the supply air temperature at set point, the SUPPLY

indicator light will be illuminated on the display module

and the default reading on the display window will be the

supply temperature sensor reading.

When the supply air temperature enters the in-range

temperature tolerance (as selected at function code

Cd30), the in-range light will energize.

3.3.2 Evaporator Fan Operation

Opening of an evaporator fan internal protector will shut

down a unit with Normal Evaporator Fan Operation.

(CnF32 set to 2EFO). On units equipped with Single

Evaporator Fan Capability (CnF32 set to 1EFO)

additional relays are installed to allow the unit to

continue to operate on a single fan. Refer to Table 3-4.

3.3.3 Defrost Interval

Controller function code Cd27 sets two modes for

defrost initiation, either user--selected timed intervals or

automatic control. The user--selected values are 3, 6, 9,

12, or 24 hours. The factory default for the timed interval

is 12 hours.

All defrost interval times reflect the number of

compressor runtime hours since the last defrost de--ice

cycle. The minimum defrost interval under the

automatic setting is 3 hours while the maximum is 24.

Refer to Table 3-5.

Defrost interval time is not accumulated in any mode

until the defrost termination sensor reads less than

10_C (50_F).

When the unit is set to automatic control and in

perishable mode, perishable--pulldown mode, or

frozen--pulldown mode, defrost starts with an initial

defrost set to 3 hours and then adjusts the interval to the

next defrost based on the accumulation of ice on the

evaporator coil. In this way, defrosts are scheduled to

occur only when necessary.

Once setpoint has been reached infrozen operation, the

automatic control selection will set the time interval to 12

hours for the first two defrosts once the return probe is

reading below the frozen setpoint and then adjust to 24

hours thereafter.

3.3.4 Failure Action

Function code Cd29 may be operator set to allow

continued operation in the event the control sensors are

reading out of range. The factory default is full system

shutdown. Refer to Table 3-5.

3.3.5 Generator Protection

Function codes Cd31 and Cd32 may be operator set to

control start up sequence of multiple units and operating

current draw. The factory default allows on demand

starting of units and full current draw. Refer to Table 3-5.

3.3.6 Condenser Pressure Control

When configuration variable CnF14 is set to “In” the

condenser pressure control logic is activated to

maintain discharge pressures above 130 psig in low

temperature ambients. The logic turns the condenser

fan on or off in accordance with the condenser pressure

transducer reading. Refer to Table 3-4. The function is

enabled when the following conditions are met:

1. The ambient sensor reading is less than or equal to

27_C (80_F)

2. Voltage/Frequency ratio is less than or equal to 8.38

When the above conditions are met, either pressures or

timers may dictate a change of state from OFF to ON, or

ON to OFF. If the condenser fan is OFF, it will be

energized if saturated condensing pressure is greater

than 200 psig OR if the condenser fan has been OFF for

a variable time period of up to sixty seconds depending

on the ambient temperature. As the ambient

temperature increases, the amount of time that the

condenser fan is energized will correspondingly

increase towards the maximum

If the condenser fan is ON, it will de-energize only if the

saturated condensing pressure is less than 130 psig

and the condenser fan has been running for a minimum

of thirty seconds depending on the ambient

temperature.

3.3.7 Arctic Mode

With arctic mode enabled, (configuration variable

CnF29 set to “In”) there will be a 30 minute time delay at

startup if the ambient is colder than --10.0_C. (14 °F)

When the START/STOP switch is placed in the “I” (ON)

position the controller will energize the compressor

crankcase heater . Operation of the heater will warm the

oil and boil off any liquid refrigerant that may be present

in the crankcase.

If Pre-Trip is initiated during the 30 minute time period,

Pre-Trip will be allowed to run normally. Once Pre-Trip is

over, the controller will revert to its normal control mode

logic. Refer to Table 3-4.

3.3.8 Perishable Mode -- Conventional

The unit is capable of maintaining supply air

temperature to within ¦0.25_C (¦0.5_F) of set point.

Supply air temperature is controlled by positioning of the

suction modulation valve (SMV), cycling of the

compressor and cycling of the heaters.

When pulling down from a temperature that is more than

5_C (9_F) above set point, the SMV will open to reduce

the pulldown time. However, pressure and current limit

functions may restrict the valve, if either exceeds the

preset value.

The Operational Software is designed so the SMV will

begin to close as the set point is reached. The SMV will

continue to close and restrict refrigerant flow until the

capacity of the unit and the load are balanced.

If the temperature drops below the set point, the

compressor will remain running for a few minutes. This

is to accommodate any initial undershoot which might

occur. After this time has expired and the temperature is

0.2_C (0.4_F) or greater below the set point, the

compressor will be turned OFF.

If the temperature drops to 0.5_C (0.9_F) below set

point, the heaters will be energized . The heaters will

Page 34 of 122

3-5 T-285

de-energize when the temperature rises to 0.2_C

(0.4_F) below the set point. The compressor will not

restart until the temperature rises to 0.2_C (0.4_F)

above the set point and three minutes have elapsed

since the last compressor turn off.

3.3.9 Perishable Mode -- Economy

The economy mode is an extension of the conventional

mode and is applicable to units with two speed

evaporator fan motors. The mode is activated when the

setting of function code Cd34 is “ON”. Economy mode is

provided for power saving purposes. Economy mode

could be utilized in the transportation of temperature

tolerant cargo or non-respiration items which do not

require high airflow for removing respiration heat. There

is no active display indicator that economy mode has

been activated. To check for economy mode, perform a

manual display of code Cd34.

In order to achieve economy mode, a perishable set

point must be selected prior to activation. When

economy mode is active, the evaporator fans will be

controlled as follows:

At the start of each cooling or heating cycle, the

evaporator fans will be run in high speed for three

minutes. They will then be switched to low speed any

time the supply air temperature is within ¦ 0.25_C

(0.45_F) of the set point and the return air temperature

is less than or equal to the supply air temperature + 3_C

(5.4_F). The fans will continue to run in low speed for

one hour. At the end of the hour, the evaporator fans will

switch back to high speed and the cycle will be repeated.

3.3.10 Perishable Mode -- Dehumidification

The dehumidification mode is provided to reduce the

humidity levels inside the container. The mode is

activated when a humidity value is set at at function

code Cd33. The display module SUPPLY led will flash

ON and OFF every second to indicate that the

dehumidification mode is active. Once the Mode is

active and the following conditions are satisfied, the

controller will activate the heat relay to begin

dehumidification.

1. The humidity sensor reading is above the set point.

2. The Supply air temperature is less than 0.25_C

above set point.

3. The heater debounce timer (three minutes) has

timed out.

4. Heater termination thermostat (HTT) is closed.

If the above conditions remain true for at least one hour

the evaporator fans will switch from high to low speed

operation. The evaporator fan speed will switch every

hour thereafter as long as all conditions are met (see

Bulb Mode section for different evaporator fan speed

options). If any condition except for item (1) becomes

false OR if the relative humidity sensed is 2% below the

dehumidification set point, the high speed evaporator

fans will be energized.

In the dehumidification mode power is applied to the

defrost and drain pan heaters. This added heat load

causes the controller to open the suction modulating

valve to match the increased heat load while still holding

the supply air temperature very close to the set point.

Opening the modulating valve reduces the temperature

of the evaporator coil surface, which increases the rate

at which water is condensed from the passing air.

Removing water from the air reduces the relative

humidity. When the relative humidity sensed is 2%

below the set point , the controller de-energizes the heat

relay. The controller will continue to cycle heating to

maintain relative humidity below the selected set point.

If the mode is terminated by a condition other than the

humidity sensor, e.g., an out-of-range or compressor

shutdown condition, the heat relay is de-energized

immediately.

Two timers are activated in the dehumidification mode

to prevent rapid cycling and consequent contactor wear.

They are:

1. Heater debounce timer (three minutes).

2. Out-of-range timer (five minutes).

The heater debounce timer is started whenever the

heater contactor status is changed. The heat contactor

remains energized (or de-energized) for at least three

minutes even if the set point criteria are satisfied.

The out-of-range timer is started to maintain heater

operation during a temporary out-of-range condition. If

the supply air temperature remains outside of the user

selected in-range setting for more than five minutes, the

heaters will be de-energized to allow the system to

recover. The out-of-range timer starts as soon as the

temperature exceeds the in-range tolerance value set

by function code Cd30.

3.3.11 Perishable, Dehumidification -- Bulb Mode

Bulb mode is an extension of the dehumidification mode

which allows changes to the evaporator fan speed

and/or defrost termination set points.

Bulb mode is active when configuration code Cd35 is set

to “Bulb”. Once the bulb mode is activated, the user may

then change the dehumidification mode evaporator fan

operation from the default (speed alternates from low to

high each hour) to constant low or constant high speed.

This is done by toggling function code Cd36 from its

default of “alt” to “Lo” or “Hi” as desired. If low speed

evaporator fan operation is selected, this gives the user

the additional capability of selecting dehumidification

set points from 60 to 95% (instead of the normal 65 to

95%).

In addition, if bulb mode is active, function code Cd37

may be set to override the previous defrost termination

thermostat settings. (Refer to paragraph 4.10.4) The

temperature at which the defrost termination thermostat

will be considered “open” may be changed [in 0.1_C

(0.2_F) increments] to any value between 25.6_C

(78_F) and 4_C (39.2_F). The temperature at which the

defrost termination thermostat is considered closed for

interval timer start or demand defrost is 10_C (50_F) for

“open values from 25.6_C down to a 10_C setting. For

“open” values lower than 10_C, the “closed” values will

decrease to the same value as the “open” setting.

Bulb mode is terminated when:

1. Bulb mode code Cd35 is set to “Nor.”

2. Dehumidification code Cd33 is set to “Off.”

3. The user changes the set point to one

that is in the frozen range.

When bulb mode is disabled by any of the above, the

evaporator fan operation for dehumidification reverts to

“alt” and the DTS termination setting resets to the value

determined by controller configuration variable CnF41.

Page 35 of 122

T-285 3-6

3.3.12 Temperature Control -- Frozen Mode

With configuration variable CnF26 set to --10_C the

frozen mode of operation is active with set points at or

below --10_C (+14_F). With the variable set to --5_C, the

frozen mode is active at or below --5_C (+23_F).

When in the frozen mode the controller maintains the

return air temperature at set point, the RETURN

indicator light will be illuminated on the display module

and the default reading on the display window will be the

return air probe reading.

When the return air temperature enters the in-range

temperature tolerance as selected at function code

Cd30, the in-range light will energize.

3.3.13 Frozen Mode -- Conventional

Frozen range cargos are not sensitive to minor

temperature changes. The method of temperature

control employed in this range takes advantage of this

fact to greatly improve the energy efficiency of the unit.

Temperature control in the frozen range is

accomplished by cycling the compressor on and off as

the load demand requires. The unit will operate in the

conventional frozen mode when the controller set point

is at or below the frozen range and function code CD34

is set to “OFF”

If the return air temperature in the container drops 0.2_C

(0.4_F) below the set point, the compressor is cycled

off. When the temperature is greater than 0.2_C (0.4_F)

above the set point and the three minute time delay has

been met, the compressor will restart. The unit will

always operate at full capacity, and the suction

modulation valve will open as allowed by current and

pressure limiting.

NOTE

On start up of the unit, SMV will reset to a known

open position. This is accomplished by assum- ing the valve was fully open, driving it fully

closed, resetting the percentage open to zero,

then opening to a known 21% staging position.

To prevent rapid cycling of the compressor, a three

minute compressor off time must be satisfied before the

compressor will restart. Under a condition of rapidly

changing return air temperature, the time delay may

allow the return air temperature to rise slightly above set

point temperature before the compressor can restart.

3.3.14 Frozen Mode -- Economy

In order to activate economy frozen mode operation, a

frozen set point temperature must be selected. The

economy mode is active when function code Cd34 is set

to “ON”. When economy mode frozen is active, the

system will perform normal frozen mode operations

except that the entire refrigeration system, excluding

the controller, will be turned off when the control

temperature is less than or equal to the set point -- 2_C.

After an off-cycle period of 60 minutes, the unit will turn

on high speed evaporator fans for three minutes, and

then check the control temperature. If the control

temperature is greater than or equal to the set point +

0.2_C., the unit will restart the refrigeration system and

continue to cool until the previously mentioned off-cycle

temperature criteria are met. If the control temperature

is less than the set point + 0.2_C, the unit will turn off the

evaporator fans and restart another 60 minute off-cycle.

3.4 CONTROLLER ALARMS

Alarm display is an independent controller software

function. If an operating parameter is outside of

expected range or a components does not return the

correct signals back to the controller an alarm is

generated. A listing of the alarms is provided in

Table 3-6.

The alarm philosophy balances the protection of the

refrigeration unit and that of the refrigerated cargo. The

action taken when an error is detected always considers

the survival of the cargo. Rechecks are made to confirm

that an error actually exists.

Some alarms requiring compressor shutdown have

time delays before and after to try to keep the

compressor on line. An example is alarm code “LO”,

(low main voltage), when a voltage drop of over 25%

occurs, an indication is given on the display, but the unit

will continue to run.

An alarm is indicated by flashing an alarm code on the

display panel, and for some alarms, by the alarm light

illuminating.

When an Alarm Occurs:

a. The red alarm light will illuminate for “20 series”

alarms, and alarm code number AL55.

b. If a detectable problem is found to exist, its alarm

code will be alternately displayed with the set point on

the left display.

c. The user should scroll through the alarm list to deter- mine what alarms exist or have existed. Alarms must

be diagnosed and corrected before the Alarm List can

be cleared.

To Display Alarm Codes :

a. While in the Default Display mode, press the ALARM

LIST key. This accesses the Alarm List Display Mode,

which displays any alarms archived in the Alarm

Queue.

b. The alarm queue stores up to 16 alarms in the se- quence in which they occurred. The user may scroll

through the list by depressing an ARROW key.

c. The left display will show “AL##,” where ## is the

alarm number sequentially in the queue.

d. The right display will show the actual alarm code.

“AA##” will display for an active alarm, where “##” is

the alarm code. Or “IA##” will display for an inactive

alarm, See Table 3-6.

e. “END” is displayed to indicate the end of the alarm list

if any alarms are active.

f. “CLEAr” is displayed if all alarms are inactive. The

alarm queue may than be cleared by pressing the EN- TER key. The alarm list will clear and “-- -- -- -- --” will

be displayed.

Page 36 of 122

3-7 T-285

3.5. UNIT PRE-TRIP DIAGNOSTICS

Pre--Trip Diagnostics is an independent controller

function which will suspend normal refrigeration

controller activities and provide preprogrammed test

routines. The test routines include Auto Mode testing,

which automatically preforms a pre programmed

sequenced of tests, or Manual Mode testing, which

allows the operator to select and run any of the

individual tests.

CAUTION

Pre-trip inspection should not be per- formed with critical temperature cargoes in

the container.

CAUTION

When Pre-Trip key is pressed, dehumidifi- cation and bulb mode will be deactivated.

At the completion of Pre-Trip activity, dehu- midification and bulb mode must be reacti- vated.

Testing may be initiated by use of the Key Pad or via

communication, but when initiated by communication

the controller will execute the entire battery of tests

(auto mode).

At the end of a pre-trip test, the message “P,” “rSLts”

(pretest results) will be displayed. Pressing the ENTER

key will allow the user to see the results for all subtests.

The results will be displayed as “PASS” or “FAIL” for all

the tests run to completion.

A detailed description of the pre-trip tests and test codes

is provided in Table 3-7, page 3-20. detailed operating

instructions are provided in paragraph 4.8.

3.6 DataCORDER

3.6.1 Description

The Carrier Transicold “DataCORDER,” software is

integrated into the controller and serves to eliminate the

temperature recorder and paper chart. The

DataCORDER functions may be accessed by key pad

selections and viewed on the display module. The unit is

also fitted with interrogation connections which may be

used with the Carrier Transicold Data Reader to down

load data. A personal computer with Carrier Transicold

Data View software may also be used to download data

and configure settings. The DataCORDER consists of:

Configuration Software

Operational Software

Data Storage Memory

Real Time Clock (with internal battery backup)

Six thermistor inputs

Interrogation Connections

Power supply (battery pack).

The DataCORDER performs the following functions:

a. Logs data at 15, 30, 60 or 120 minute intervals and

stores two years’ of data (based on one hour interval).

b. Records and displays alarms on the display module.

c. Records results of pre--trip testing.

d. Records DataCORDER and temperature control

software generated data and events as follows:

Container ID Change

Software Upgrades

Alarm Activity

Battery Low (Battery Pack)

Data Retrieval

Defrost Start and End

Dehumidification Start and End

Power Loss (w/wo battery pack)

Power Up (w/wo battery pack)

Remote Probe Temperatures in the Container

(USDA Cold treatment and Cargo probe recording)

Return Air Temperature

Set Point Change

Supply Air Temperature

Real Time Clock Battery (Internal Battery) Replace- ment

Real Time Clock Modification

Trip Start

ISO Trip Header (When entered via Interrogation

program)

Economy Mode Start and End

“Auto 2” Pre-Trip Start and End

Bulb Mode Start

Bulb Mode changes

Bulb Mode End

USDA Trip Comment

Humidification Start and End

USDA Probe Calibration

3.6.2 DataCORDER Software

The DataCORDER Software is subdivided into the

Configuration Software, Operational Software and the

Data Memory.

a. Operational Software

The Operational Software reads and interprets inputs

for use by the Configuration Software. The inputs are

labeled Function Codes. There are 35 functions (see

Table 3-8, page 3-24) which the operator may access to

examine the current input data or stored data. To access

these codes, do the following:

1 Press the ALT. MODE & CODE SELECT keys.

2 Press an arrow key until the left window displays the

desired code number. The right window will display

the value of this item for five seconds before returning

to the normal display mode.

3 If a longer time is desired, press the ENTER key to

extend the time to 30 seconds.

Page 37 of 122

T-285 3-8

Table 3-2 DataCORDER Configuration Variables

CONFIGURATION NO. TITLE DEFAULT OPTION

dCF01 (Future Use) ---- ----

dCF02 Sensor Configuration 2 2,5,6,9,54,64,94

dCF03 Logging Interval (Minutes) 60 15,30,60,120

dCF04 Thermistor Format Short Low, Normal

dCF05 Thermistor Sampling Type A A,b,C

dCF06 Controlled Atmosphere/Humidity Sampling Type A A,b

dCF07 Alarm Configuration USDA Sensor 1 A Auto, On, Off

dCF08 Alarm Configuration USDA Sensor 2 A Auto, On, Off

dCF09 Alarm Configuration USDA Sensor 3 A Auto, On, Off

dCF10 Alarm Configuration Cargo Sensor A Auto, On, Off

b. Configuration Software

The configuration software controls the recording and

alarm functions of the DataCORDER. Reprogramming

to the factory installed configuration is achieved via the

same configuration card as the unit control module

software. Changes to the software may be made made

using the Data View integration device. A listing of the

configuration variables is provided in Table 3-2.

Descriptions of DataCORDER operation for each

variable setting are provided in the following

paragraphs.

3.6.3 Sensor Configuration (dCF02)

Two modes of operation may be configured, the

Standard Mode and the Generic Mode.

a. Standard Mode

In the standard mode, the user may configure the

DataCORDER to record data using one of seven

standard configurations. The seven standard

configuration variables, with their descriptions, are

listed in Table 3-3.

The six thermistor inputs (supply, return, USDA #1, #2,

#3 and cargo probe) and the humidity sensor input will

be generated by the DataCORDER. An example of a

report using a standard configuration is shown in

Figure 3- 5.

NOTE

The DataCORDER software uses the supply

and return recorder sensors. The temperature

control software uses the supply and return

temperature sensors.

b. Generic Mode

The generic recording mode allows user selection of the

network data points to be recorded. The user may select

up to a total of eight data points for recording. A list of the

data points available for recording follows. Changing the

configuration to generic and selecting which data points

to record may be done using the Carrier Transicold Data

Retrieval Program.

1. Control mode

2. Control temperature

3. Frequency

4. Humidity

5. Phase A current

6. Phase B current

7. Phase C current

8. Main voltage

9. Suction modulation valve percentage

10. Discrete outputs (Bit mapped -- require special

handling if used)

11. Discrete inputs (Bit mapped -- require special

handling if used)

12. Ambient sensor

13. Compressor suction sensor

14. Compressor discharge sensor

15. Return temperature sensor

16. Supply temperature sensor

17 Defrost temperature sensor

18. Discharge pressure transducer

19. Suction pressure transducer

20. Condenser pressure transducer

Table 3-3 DataCORDER Standard Configurations

Standard

Config. Description

2 sensors

(dCF02=2) 2 thermistor inputs(supply & return)

5 sensors

(dCF02=5)

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

6 sensors

(dCF02=6)

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 humidity input

9 sensors

(dCF02=9) Not Applicable

6 sensors

(dCF02=54)

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 cargo probe (thermistor input)

7 sensors

(dCF02=64)

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 humidity input

1 cargo probe (thermistor input)

10 sensors

(dCF02=94)

2 thermistor inputs(supply & return)

3 USDA thermistor inputs

1 humidity input

1 cargo probe (thermistor input)

3 C.A. inputs (NOT APPLICABLE)

Page 38 of 122

3-9 T-285

Raw Data Report for ABC1234567

May 31, 2001 to Jun 04, 2001

System Configuration at the Time of Interrogation:

Interrogated On Sept 05, 2001

Extracted by DataLine Rev 1.0.0

Controller Software: 5120

Controller Serial #: 04163552

Bill of Lading #: 1

Origin: Origin Date:

Destination: Discharge Date:

Comment: DataLine Tool

Probe Calibration Readings: USDA1: 0.0 USDA2: 0.0 USDA3: 0.0 Cargo: 0.0

Temperature Units: Centigrade

________________________________________________________________________________________

May 31, 2001

Setpoint: 1.66, Container : Serial : 04189552

9 Sensors Logged at 15 Minute Interval

Sensor Format Resolution

Figure 3- 5 Standard Configuration Report

Page 39 of 122

T-285 3-10

3.6.4 Logging Interval (dCF03)

The user may configure four time intervals between

data recordings. Data is logged at exact intervals in

accordance with the real time clock. The clock is factory

set at Greenwich Mean Time.

3.6.5 Thermistor Format (dCF04)

The user may configure the format in which the

thermistor readings are recorded. The low resolution is

a 1 byte format and the normal resolution is a 2 byte

format. The low requires less memory and records

temperature in 0.25°C (0.45°F) steps when in the

perishable mode or 0.5°C (0.9°F) steps when in the

frozen mode. The normal records temperature in

0.01°C (0.02°F) steps for the entire range.

3.6.6 Sampling Type (dCF05 & dCF06)

Three types of data sampling are available, average,

snapshot and USDA. When configured to average, the

average of readings taken every minute over the

recording period is recorded. When configured to

snapshot, the sensor reading at the log intervale time is

recorded. When USDA is configured the supply and

return temperature readings are averaged and the 3

USDA probe readings are snapshot.

3.6.7 Alarm Configuration (dCF07 -- dCF10)

The USDA and cargo probe alarms may be configured

to OFF, ON or AUTO.

If a probe alarm is configured to OFF, then the alarm for

this probe is always disabled.

If a probe alarm is configured to ON, then the associated

alarm is always enabled.

If the probes are configured to AUTO, they act as a

group. This function is designed to assist users who

keep their DataCORDER configured for USDA

recording, but do not install the probes for every trip. If all

the probes are disconnected, no alarms are activated.

As soon as one of the probes is installed , then all of the

alarms are enabled and the remaining probes that are

not installed will give active alarm indications.

The DataCORDER will record the initiation of a pre-trip

test (refer to paragraph 3.5) and the results of each of

the tests included in pre--trip. The data is time-stamped

and may be extracted via the Data Retrieval program.

Refer to Table 3-9 for a description of the data stored in

the DataCORDER for each corresponding Pre-Trip test.

3.6.8 DataCORDER Power-Up

The DataCORDER may be powered up in any one of

four ways:

1. Normal AC power: The DataCORDER is powered

up when the unit is turned on via the stop-start switch.

2. Controller DC battery pack power: If a battery pack

is installed, the DataCORDER will power up for

communication when an interrogation cable is plugged

into an interrogation receptacle.

3. External DC battery pack power: A 12 volt battery

pack may also be plugged into the back of the

interrogation cable, which is then plugged into an

interrogation port. No controller battery pack is required

with this method.

4. Real Time Clock demand: If the DataCORDER is

equipped with a charged battery pack and AC power is

not present, the DataCORDER will power up when the

real time clock indicates that a data recording should

take place. When the DataCORDER is finished

recording, it will power down.

During DataCORDER power-up, while using

battery-pack power, the controller will perform a

hardware voltage check on the battery. If the hardware

check passes, the Controller will energize and perform a

software battery voltage check before DataCORDER

logging. If either test fails, the real time clock battery

power-up will be disabled until the next AC power cycle.

Further DataCORDER temperature logging will be

prohibited until that time.

An alarm will be generated when the battery voltage

transitions from good to bad indicating that the battery

pack needs recharging. If the alarm condition persists

for more than 24 hours on continuous AC power, the

battery pack needs replacement.

3.6.9 Pre-Trip Data Recording

The DataCORDER will record the initiation of a pre-trip

test (refer to paragraph 3.5) and the results of each of

the tests included in pre--trip. The data is time-stamped

and may be extracted via the Data Retrieval program.

Refer to Table 3-9 for a description of the data stored in

the DataCORDER for each corresponding Pre-Trip test.

3.6.10 DataCORDER Communications

Data retrieval from the DataCORDER can be

accomplished by using one of the following;

DataReader, DataLine/DataView or a communications

interface module.

NOTE

A DataReader, DataLine/DataView or a com- munications interface module display of Com- munication Failed is caused by faulty data

transfer between the datacorder and the data

retrival device. Common causes include:

1. Bad cable or connection between

DataCORDER and data retrieval device.

2. PC communication port(s) unavailable or

misassigned.

3. Chart Recorder Fuse (FCR) blown .

a. DataReader

The Carrier Transicold Data Reader (see Figure 3- 6) is a

simple to operate hand held device designed to extract

data from the DataCORDER and then upload it to a

personal computer. The Data Reader has the ability to

store multiple data files. Refer to Data Retrieval manual

62-10629 for a detailed explanation of the DataReader.

DataReader

Figure 3- 6 Data Reader

b. DataLine

The DataLINE software for a personal computer is

supplied on both floppy disks and CD. This software

allows interrogation, configuration variable assignment,

screen view of the data, hard copy report generation, cold

treatment probe calibration and file management. Refer to

Data Retrieval manual 62-10629 for a more detailed

explanation of the DataLINE interrogation software. The

Page 40 of 122

3-11 T-285

DataLine manual may be found on the net at

www.contaner.carrier.com

c. Communications Interface Module

The communications interface module is a slave

module which allows communication with a master

central monitoring station. The module will respond to

communication and return information over the main

power line.

With a remote monitoring unit installed, all functions and

selectable features that are accessible at the unit may

be performed at the master station. Retrieval of all

DataCORDER reports may also be performed. Refer to

the master system technical manual for further

information.

3.6.11 USDA Cold Treatment

Sustained cold temperature has been employed as an

effective postharvest method for the control of

Mediterranean and certain other tropical fruit flies.

Exposing infested fruit to temperatures of 2.2 degrees

Celsius (36_F) or below for specific periods results in

the mortality of the various stages of this group of

insects.

In response to the demand to replace fumigation with

this environmentally sound process, Carrier has

integrated Cold Treatment capability into its

microprocessor system. These units have the ability to

maintain supply air temperature within one-quarter

degree Celsius of setpoint and record minute changes

in product temperature within the DataCORDER

memory, thus meeting USDA criteria. Information on

USDA is provided in the following subparagraphs

a. USDA Recording

A special type of recording is used for USDA cold

treatment purposes. Cold treatment recording requires

three remote temperature probes be placed at

prescribed locations in the cargo. Provision is made to

connect these probes to the DataCORDER via

receptacles located at the rear left-hand side of the unit.

Four or five receptacles are provided. The four three-pin

receptacles are for the probes and fifth, five pin,

receptacle is the rear connection for the theInterrogator.

The probe receptacles are sized to accept plugs with

tricam coupling locking devices. A label on the back

panel of the unit shows which receptacle is used for

each probe.

The standard DataCORDER report displays the supply

and return air temperatures. The cold treatment report

displays USDA #1, #2, #3 and the supply and return air

temperatures. Cold treatment recording is backed up by

a battery so recording can continue if AC power is lost.

b. USDA/ Message Trip Comment

A special feature is incorporated which allows the user

to enter a USDA (or other) message at the head of a

data report. The maximum message length is 78

characters. Only one message will be recorded per day.

3.6.12 USDA Cold Treatment Procedure

The following is a summary of the steps required to

initiate a USDA Cold Treatment.

a. Calibrate the three USDA probes by ice bathing the

probes and performing the calibration function with

the DataReader or a personal computer. This calibra- tion procedure determines the probe offsets and

stores them in the controller for use in generating the

cold treatment report. Refer to the Data Retrieval

manual 62-10629 for more details.

b. Pre-cool the container to the treatment temperature

or below.

c. Install the DataCORDER module battery pack (if not

already installed).

d. Place the three probes. The probes are placed into

the pulp of the fruit (at the locations defined in the fol- lowing table) as the product is loaded.

Sensor 1 Place in pulp of the product located next

to the return air intake.

Sensor 2

Place in pulp of the product five feet

from the end of the load for 40 foot con- tainers, or three feet from the end of the

load for 20 foot containers. This probe

should be placed in a center carton at

one-half the height of the load.

Sensor 3

Place in pulp of product five feet from

the end of the load for 40 foot containers

or three feet from the end of the load for

20 foot containers. This probe should be

placed in a carton at a side wall at one- half the height of the load.

e. To initiate USDA Recording, connect the personal

computer and perform the configuration as follows:

1. Fill in ISO header information

2. Add a trip comment if desired

3. Configure for five probes (s, r, P1, P2, P3)

4. Configure for one hour logging interval

5. Set the sensor configuration at USDA

6. Configure for two byte memory storage format

7. Do a trip start

3.6.13 DataCORDER Alarms

Alarm display is an independent DataCORDER

function. If an operating parameter is outside of the

expected range or a component does not return the

correct signals back to the DataCORDER an alarm is

generated. The DataCORDER contains a buffer of up to

eight alarms. A listing of the DataCORDER alarms is

provided in Table 3-10, page 3-26. Refer to paragraph

3.6.7 for configuration information.

To display alarm codes:

a. While in the Default Display mode, press the ALT.

MODE & ALARM LIST keys. This accesses the Data- CORDER Alarm List Display Mode, which displays

any alarms stored in the Alarm Queue.

b. To scroll to the end of the alarm list press the UP AR- ROW. Depressing the DOWN ARROW key will scroll

the list backward.

c. The left display will show “AL#” where # is the alarms

number in the queue. The right display will show

“AA##,” if the alarm is active, where ## is the alarm

number. “IA##,” will show if the alarm is inactive

d. “END” is displayed to indicate the end of the alarm list

if any alarms are active. “CLEAr” is displayed if all the

alarms in the list are inactive.

e. If no alarms are active, the Alarm Queue may be

cleared. The exception to this rule is the DataCORD- ER Alarm Queue Full alarm (AL91) , which does not

have to be inactive in order to clear the alarm list. To

Clear the Alarm List:

1. Press the ALT. MODE & ALARM LIST keys.

2. Press the UP/DOWN ARROW key until “CLEAr” is

displayed.

3. Press the ENTER key. The alarm list will clear and “-- -- -- -- --” will be displayed.

4. Press the ALARM LIST key. “AL” will show on the left

display and “-- -- -- -- --” on the right display when

there are no alarms in the list.

5. Upon clearing of the Alarm Queue, the Alarm light will

be turned off.

Page 41 of 122

T-285 3-12

Table 3-4 Controller Configuration Variables

CONFIGURATION

NUMBER TITLE DEFAULT OPTION

CnF01 Bypass Valve Enable In Out

CnF02 Evaporator Fan Speed dS (Dual) SS (Single)

CnF03 Control Sensors FOUr duAL

CnF04 Dehumidification Mode On OFF

CnF05 Reserved for future use ---------- n/a

CnF06 Condenser Fan Speed Select OFF (Single) On (Variable)

CnF07 Unit Selection, 20FT/ 40FT/45FT 40ft 20ft,45

CnF08 Single Phase/Three Phase Motor 1Ph 3Ph

CnF09 Refrigerant Selection r134a r12, r22, bLEnd

CnF10 Two Speed Compressor Logic Out (Single) In (Dual)

CnF11 Defrost “Off” Selection noOFF OFF

CnF12 TXV/Solenoid Quench Valve Out (TXV) In (Solenoid)

CnF13 Unloader Out In

CnF14 Condenser Pressure Control (CPC) In Out

CnF15 Discharge Temperature Sensor Out In

CnF16 DataCORDER Present On (Yes) OFF (No)

CnF17 Discharge Pressure Sensor Out (No) In (Yes)

CnF18 Heater Old (Low Watt) nEW (High Watt)

CnF19 Controlled Atmosphere Out (No) In (Yes)

CnF20 Suction Pressure Sensor Out (No) In (Yes)

CnF21 Autotransformer Out In

CnF22 Economy Mode Option OFF Std, Full

CnF23 Defrost Interval Timer Save Option noSAv SAv

CnF24 Advanced Pre-Trip Enhanced Test Series Option Auto Auto2, Auto 3

CnF25 Pre-Trip Test Points/Results Recording Option rSLtS dAtA

CnF26 Heat Lockout Change Option Set to --10_C Set to --5_C

CnF27 Suction Temperature Display Option Out In

CnF28 Bulb Mode Option NOr bULb

CnF29 Arctic Mode Out In

CnF30 Compressor Size 41 CFM 37 CFM

CnF31 Probe Check Option Std SPEC

CnF32 Single Evaporator Fan Option 2EF0 1EF0

CnF33 Snap Freeze Option OFF SnAP

CnF34 Degree Celsius Lockout Option bOth _F

CnF35 Humidification Mode OFF On

CnF36 SMV Type 1 (standard) 2, 3 (stepper)

CnF37 Electronic Temperature Recorder rEtUR SUPPL, bOth

CnF38 Quench Bypass Valve Out In

CnF39 Expanded Current Limit Range Out In

CnF40 Demand Defrost Out In

CnF41 Lower DTT Setting Out In

CnF42 Auto Pre--trip Start Out In

CnF47 Fresh Air Vent Position Sensor OFF UPP, LOW

CnF48 CFS Override OFF On

CnF49 Datacorder Configuration Restore OFF On

CnF50 Enhanced Bulb Mode Selection OFF Bulb, dEHUM

CnF51 Timed Defrost Disable 0 0--out, 1--in

Note: Configuration numbers not listed are not used in this application. These items may appear when loading

configuration software to the controller but changes will not be recognized by the controller programming.

Page 42 of 122

3-13 T-285

Table 3-5 Controller Function Codes (Sheet 1 of 4)

Code

No. TITLE DESCRIPTION

Note: If the function is not applicable, the display will read “ -- -- -- -- -- ”

Display Only Functions

Cd01 Suction Modulation

Valve Opening (%)

Displays the SMV percent open. The right display reads 100% when the valve is

fully open and 0% when the valve is fully closed. The valve will usually be at 21%

on start up of the unit except in very high ambient temperatures.

Cd02 Quench Valve Displays state of the solenoid quench valve, open or closed.

Cd03 Not Applicable Not used

Cd04

Cd05

Cd06

Line Current,

Phase A

Line Current,

Phase B

Line Current,

Phase C

The current sensor measures current on two legs. The third unmeasured leg is

calculated based on a current algorithm. The current measured is used for control

and diagnostic purposes. For control processing, the highest of the Phase A and

B current values is used for current limiting purposes. For diagnostic processing,

the current draws are used to monitor component energization.. Whenever a

heater or a motor is turned ON or OFF, the current draw increase/reduction for

that activity is measured. The current draw is then tested to determine if it falls

within the expected range of values for the component. Failure of this test will re- sult in a pre-trip failure or a control alarm indication.

Cd07 Main Power Voltage The main supply voltage is displayed.

Cd08 Main Power Fre- quency

The value of the main power frequency is displayed in Hertz. The frequency dis- played will be halved if either fuse F1 or F2 is bad (alarm code AL21).

Cd09 Ambient Tempera- ture The ambient sensor reading is displayed.

Cd10 Compressor Suction

Temperature Compressor suction temperature sensor reading is displayed.

Cd11 Compressor Dis- charge Temperature Compressor discharge temperature sensor reading is displayed.

Cd12 Compressor Suction

Pressure Compressor suction pressure transducer reading is displayed.

Cd13 Condenser Pressure Condenser pressure transducer reading is displayed.

Cd14 Compressor Dis- charge Pressure Compressor discharge pressure transducer reading is displayed.

Cd15 Unloader Valve (On--

Off) Not used in this application

Cd16 Compressor Motor

Hour Meter

Records total hours of compressor run time. Total hours are recorded in incre- ments of 10 hours (i.e., 3000 hours is displayed as 300).

Cd17 Relative Humidity

(%)

Humidity sensor reading is displayed. This code displays the relative humidity, as

a percent value.

Cd18 Software Revision # The software revision number is displayed.

Cd19 Battery Check

This code checks the Controller/DataCORDER battery pack. While the test is run- ning, “btest” will flash on the right display, followed by the result. “PASS” will be

displayed for battery voltages greater than 7.0 volts. “FAIL” will be displayed for

battery voltages between 4.5 and 7.0 volts, and “-- -- -- -- --” will be displayed for

battery voltages less than 4.5 volts. After the result is displayed for four seconds,

“btest” will again be displayed, and the user may continue to scroll through the

various codes.

Cd20 Config/Model # This code indicates the dash number of the model for which the Controller is con- figured (i.e., if the unit is a 69NT40-489-100, the display will show “89100”).

Cd21

Humidity Water

Pump/Atomizer

Status

This code displays the status of the humidity water pump (-- -- -- -- --, forward, re- verse or off). If not configured, the mode is permanently deactivated and will dis- play “-- -- -- -- --.”

Page 43 of 122

T-285 3-14

Table 3-5 Controller Function Codes (Sheet 2 of 4)

Cd22 Compressor Speed The status of the compressor is displayed (high, low or off).

Cd23 Evaporator Fan Displays the current evaporator fan state (high, low or off).

Cd24 Controlled

Atmosphere State Not used in this application

Cd25

Compressor Run

Time Remaining Un- til Defrost

This code displays the time remaining until the unit goes into defrost (in tenths of

an hour). This value is based on the actual accumulated compressor running

time.

Cd26 Defrost Temperature

Sensor Reading Defrost temperature sensor reading is displayed.

Configurable Functions

NOTE

Function codes Cd27 through Cd37 are user-selectable functions. The operator can change the value of

these functions to meet the operational needs of the container.

Cd27 Defrost Interval

(Hours or Automatic)

There are two modes for defrost initiation, user--selected or automatic control.

The user--selected values are (OFF), 3, 6, 9, 12, or 24 hours with a factory de- fault of 12 hours.

Automatic defrost starts with an initial defrost at 3 hours and then adjusts the in- terval to the next defrost based on the accumulation of ice on the evaporator coil.

Following a start--up or after termination of a defrost, the time will not begin count- ing down until the defrost temperature sensor (DTS) reading falls below set point.

If the reading of DTS rises above set point any time during the timer count down,

the interval is reset and the countdown begins over. If DTS fails, alarm code AL60

is activated and control switches over to the the return temperature sensor. The

controller will act in the same manner as with the DTS except the return tempera- ture sensor reading will be used.

Defrost Interval Timer Value (Configuration variable CnF23): If the software is

configured to “SAv” (save) for this option, then the value of the defrost interval

timer will be saved at power down and restored at power up. This option prevents

short power interruptions from resetting an almost expired defrost interval, and

possibly delaying a needed defrost cycle.

NOTE

The defrost interval timer counts only during compressor run time.

Cd28 Temperature Units

(_C or _F)

This code determines the temperature units (_C or _F) which will be used for all

temperature displays. The user selects _C or _F by selecting function code Cd28

and pushing the ENTER key. The factory default value is Celsius units.

NOTE

This function code will display “--- --- --- --- ---“ if Configuration Variable CnF34 is

set to _F.

Cd29 Failure Action

(Mode)

If all of the control sensors are out of range (alarm code AL26) or there is a probe

circuit calibration failure (alarm code AL27), the unit will enter the shutdown state

defined by this setting. The user selects one of four possible actions as follows:

A -- Full Cooling (stepper motor SMV at maximum allowed opening)

B -- Partial Cooling (stepper motor SMV 11% open)

C -- Evaporator Fan Only

D -- Full System Shutdown -- Factory Default

Cd30 In-Range Tolerance

The in-range tolerance will determine the band of temperatures around the set

point which will be designated as in-range. If the control temperature is in-range,

the in-range light will be illuminated. There are four possible values:

1 = ¦ 0.5_C (¦ 0.9_F)

2 = ¦ 1.0_C (¦ 1.8_F)

3 = ¦ 1.5_C (¦ 2.7_F)

4 = ¦ 2.0_C (¦ 3.6_F) -- Factory Default

Page 44 of 122

3-15 T-285

Table 3-5 Controller Function Codes (Sheet 3 of 4)

Cd31 Stagger Start Offset

Time (Seconds)

The stagger start offset time is the amount of time that the unit will delay at start- up, thus allowing multiple units to stagger their control initiation when all units are

powered up together. The eight possible offset values are:

0 (Factory Default), 3, 6, 9, 12, 15, 18 or 21 seconds

Cd32 Current Limit

(Amperes)

The current limit is the maximum current draw allowed on any phase at any time.

Limiting the unit’s current reduces the load on the main power supply. This is ac- complished by reducing the SMV position until current draw is reduced to the set

point. When desirable, the limit can be lowered. Note, however, that capacity is

also reduced. The five values for 460vac operation are:

15, 17, 19, 21 (Factory Default), 23

Cd33

Perishable Mode

Dehumidification/Hu- midification Control

(% RH)

Relative humidity set point is available only on units configured for dehumidifica- tion. When the mode is activated, the control probe LED flashes on and off every

second to alert the user. If not configured, the mode is permanently deactivated

and “-- -- -- -- --” will display. The value can be set to “OFF.” “TEST,” or a range of

65 to 95% relative humidity in increments of 1%. [If bulb mode is active (code

Cd35) and “Lo” speed evaporator motors are selected (code Cd36) then set point

ranges from 60 to 95%.] When “TEST” is selected or test set point is entered, the

heat LED should illuminate, indicating that dehumidification mode is activated.

After a period of five minutes in the “TEST” mode has elapsed, the previously

selected mode is reinstated.

NOTE

If humidification (CnF35) is enabled, then humidification will be enabled and

dehumidification locked out at set points of 75% and above. At set points be- low 75%, dehumidification will be enabled and dehumidification locked out.

Cd34 Economy Mode

(On--Off)

Economy mode is a user selectable mode of operation provided for power saving

purposes.

Cd35 Bulb Mode

Bulb mode is a user selectable mode of operation that is an extension of dehu- midification control (Cd33). If dehumidification is set to “Off,” code Cd35 will dis- play “Nor” and the user will be unable to change it. After a dehumidification set

point has been selected and entered for code Cd33, the user may then change

code Cd35 to “bulb.” After bulb has been selected and entered, the user may then

utilize function codes Cd36 and Cd37 to make the desired changes.

Cd36 Evaporator Speed

Select

This code is enabled only if in the dehumidification mode (code Cd33) and bulb

mode (Cd35) has been set to “bulb”. If these conditions are not met, “alt” will be

displayed (indicating that the evaporator fans will alternate their speed) and the

display cannot be changed. If a dehumidification set point has been selected

along with bulb mode then “alt” may be selected for alternating speed, “Lo” for low

speed evaporator fan only, or “Hi” for high speed evaporator fan only. If a setting

other than “alt” has been selected and bulb mode is deactivated in any manner,

then selection reverts back to “alt.”

Cd37

Defrost Termination

Temperature Setting

(Bulb Mode)

This code, as with function code Cd36, is used in conjunction with bulb mode and

dehumidification. If bulb mode is active, this code allows the user to change the

defrost termination thermostat settings. If bulb mode is deactivated, the DTS set- ting returns to the default.

Page 45 of 122

T-285 3-16

Table 3-5 Controller Function Codes (Sheet 4 of 4)

Display Only Functions -- Continued

Cd38 Secondary Supply

Temperature Sensor

Code Cd38 will display the current secondary supply temperature sensor reading

for units configured for four probes. If the unit is configured with a DataCORDER,

Cd38 will display “-- -- -- -- --.” If the DataCORDER suffers a failure, (AL55) Cd38

will display the supply recorder sensor reading.

Cd39 Secondary Return

Temperature Sensor

Code Cd39 will display the current secondary return temperature sensor reading

for units configured for four probes. If the unit is configured with a DataCORDER,

Cd39 will display “-- -- -- -- --.” If the DataCORDER suffers a failure, (AL55) Cd39

will display the return recorder sensor reading.

Cd40 Container Identifica- tion Number

Code Cd40 is configured at commissioning to read a valid container identification

number. The reading will not display alpha characters, only the numeric portion of

the number will display.

Cd41

Cd42 Not Applicable Scroll Units Only

The following Configuration Codes (Cd43--45) highlighted in gray apply to Software Revisions

5123 and 5124 ONLY.

Cd43 Air Slide Mode

This code is only applicable to units with Auto Fresh. If not configured, the mode

is permanently deactivated and CD 43 will display “-- -- -- -- --”. When mode is

available, it can be set to “OFF”, “AUTO”, “USER”, or “TEST”. After “AUTO” or

“USER” mode has been selected and entered, the user may use function code 45

and 46 to make desired changes.

Cd44 Air Slide Opening

This code is only applicable to units with Auto Fresh. If not configured, the per- cent opening is permanently deactivated and Cd44 will display

”-- -- -- -- -- “. When percent opening is available, it can be set to 0% to 100%.

Cd45 Air Slide Timer This code is enabled only if Air Slide Mode is “AUTO” or “USER”. If not, Cd45 will

display “-- -- -- -- --”.

In software revision 5125, Codes Cd43--Cd45 were consolidated into Code Cd43,

and Codes Cd44--Cd45 were reassigned.

Cd43 AutoFresh Mode

Code Cd43 is a user selectable mode of operation that allows the opening and

closing of a mechanical air vent door via a stepper motor. These selection modes

are as follows:

OFF -- Air makeup vent will remain closed.

User -- Allows for manual selection of the setting.

Delay --The opening of the door is based on selected time, return temperature

and flow rate (percent opened).

gASLM -- The opening is based percent open and CO2 and O2 selectable limits

(LM). This selection is only active if the unit has a CO2 sensor.

TEST / CAL (CO2 sensor option units only) -- The door will fully open and close

to allow the user to inspect its

operation. If CAL is selected the

controller will zero calibrate the

CO2 sensor input.

If the unit is not configured with AutoFresh the CD43 will display “--------”.

Cd44 AutoFresh Values

Code Cd44 will display CO2 and O2 concentrations and limits. If the unit is not

configured for AutoFresh or a CO2 sensor is not installed , CD44 will dis- play“--------” .

Cd45 Vent Position Sensor

(VPS)

Code Cd45 will display whenever the control detects movement via the sensor

unless alarm 50 is active. The code will display for 30 seconds, then time out and

return to the normal display mode. If the Temperature unit is _F, the VPS units will

be CFM and in _C the VPS units shall be CMH.

Cd46 Not Used --

Cd47 Variable Economy

Temperature Setting

The variable temperature “_C or _F” setting is used with economy mode. Func- tion code is “--------“ when unit is not configured for economy mode.

Cd48

Dehumidification/

Bulb Mode

Parameter Selection

Code CD48 is used to determine limits (between 60%--95%) for dehumidification

and/or bulb mode (CNF28) when active.

Cd49 Days Since Last

Successful Pre--Trip

Code CD49 will display the number of days since the last successful Auto1,

Auto2 or Auto3 pre--trip sequence.

Page 46 of 122

3-17 T-285

Figure 3- 1Table 3-6 Controller Alarm Indications (Sheet 1 of 3)

Code

No. TITLE DESCRIPTION

AL11 Evaporator Motor 1

IP Trip

Alarm 11 is applicable to units with Single Evaporator Fan Capability (CnF32 set

to 1EFO) only. The alarm is triggered if the evaporator fan motor #1 internal pro- tector opens. If the alarm is active, probe check is deactivated.

AL12 Evaporator Motor 2

IP Trip

Alarm 12 is applicable to units with Single Evaporator Fan Capability (CnF32 set

to 1EFO) only. The alarm is triggered if the evaporator fan motor #2 internal pro- tector opens. If the alarm is active, probe check is deactivated.

AL20 Control Circuit Fuse

Open (24 vac)

Alarm 20 is triggered by control power fuse (F3) opening and will cause the soft- ware shutdown of all control units. This alarm will remain active until the fuse is

replaced.

AL21 Micro Circuit Fuse

Open (18 vac)

Alarm 21 is triggered by one of the fuses (F1/F2) being opened on 18 volts AC

power supply to the Controller. The suction modulation valve (SMV) will be

opened and current limiting is halted. Temperature control will be maintained by

cycling the compressor.

AL22 Evaporator Fan Mo- tor Safety

Alarm 22 responds to the evaporator motor internal protectors. On units with Nor- mal Evaporator Fan Operation (CnF32 set to 2EFO) the alarm is triggered by

opening of either internal protector. It will disable all control units until the motor

protector resets. On units with Single Evaporator Fan Capability (CnF32 set to

1EFO) the alarm is triggered by opening of both internal protectors. It will disable

all control units until a motor protector resets.

AL23 KA2--KB10 Jumper

Disconnected

Alarm 23 is triggered by a missing jumper wire. The alarm will stay active until

the jumper wire is reconnected. On units with Single Evaporator Fan Capability

(CnF32 set to 1EFO) this alarm is deactivated.

AL24 Compressor Motor

Safety

Alarm 24 is triggered by the opening of the compressor motor internal protector.

This alarm will disable all control units except for the evaporator fans and will re- main active until the motor protector resets. This alarm triggers the failure action

code set by Function Code Cd29.

AL25 Condenser Fan Mo- tor Safety

Alarm 25 is triggered by the opening of the condenser motor internal protector

and will disable all control units except for the evaporator fans. This alarm will

remain active until the motor protector resets. This alarm is deactivated if the unit

is operating on water cooled condensing.

AL26

All Supply and Re- turn temperature

Control Sensors

Failure

Alarm 26 is triggered if the Controller determines that all of the control sensors

are out-of-range. This can occur for box temperatures outside the range of

--50_C to +70_C (--58_F to +158_F). This alarm triggers the failure action code

set by Function Code Cd29.

AL27 Probe Circuit Cal- ibration Failure

The Controller has a built-in Analog to Digital (A-D) converter, used to convert

analog readings (i.e. temperature sensors, current sensors, etc.) to digital read- ings. The Controller continuously performs calibration tests on the A-D converter.

If the A-D converter fails to calibrate for 30 consecutive seconds, this alarm is

activated.This alarm will be inactivated as soon as the A-D converter calibrates.

AL50 Fresh Air Position

Sensor (VPS)

Alarm 50 is activated whenever the sensor is outside the valid range. There is a

5 minute adjustment period where the user can change the vent position without

generating an alarm event. The sensor requires 5 minutes of no movement to

confirm stability. If the vent position changes at any point beyond the 5 minute

adjustment period, the sensor will generate an alarm event. The alarm is trig- gered off when the unit power cycles and the sensor is within valid range.

AL51 Alarm List Failure

During start-up diagnostics, the EEPROM is examined to determine validity of its

contents. This is done by testing the set point and the alarm list. If the contents

are invalid, Alarm 51 is activated. During control processing, any operation in- volving alarm list activity that results in an error will cause Alarm 51 to be acti- vated. Alarm 51 is a “display only” alarm and is not written into the alarm list.

Pressing the ENTER key when “CLEAr” is displayed will result in an attempt to

clear the alarm list. If that action is successful (all alarms are inactive), Alarm 51

will be reset.

AL52 Alarm List Full

Alarm 52 is activated whenever the alarm list is determined to be full; at start-up

or after recording an alarm in the list. Alarm 52 is displayed, but is not recorded in

the alarm list. This alarm can be reset by clearing the alarm list. This can be done

only if all alarms written in the list are inactive.

Page 47 of 122

T-285 3-18

Table 3-6 Controller Alarm Indications (Sheet 2 of 3)

AL53 Battery Pack Failure

Alarm 53 is caused by the battery pack charge being too low to provide sufficient

power for battery-backed recording. Renew replaceable batteries. If this alarm

occurs on start up, allow a unit fitted with rechargeable batteries to operate for up

to 24 hours to charge rechargeable batteries sufficiently to deactivate the alarm

AL54

Primary Supply Tem- perature Sensor

Failure (STS)

Alarm 54 is activated by an invalid primary supply temperature sensor reading

that is sensed outside the range of --50 to +70_C (--58_F to +158_F) or if the

probe check logic has determined there is a fault with this sensor. If Alarm 54 is

activated and the primary supply is the control sensor, the secondary supply sen- sor will be used for control if the unit is so equipped. If the unit does not have a

secondary supply temperature sensor, and AL54 is activated, the primary return

sensor reading, minus 2_C will be used for control.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm

AL55 DataCORDER

Failure

This alarm activates to indicate the DataCORDER has a software failure. To clear

this alarm, reconfigure the unit to the current model number. This failure may be

the result of a voltage dip in excess of 25%.

AL56

Primary Return Tem- perature Sensor

Failure (RTS)

Alarm 56 is activated by an invalid primary return temperature sensor reading

that is outside the range of --50 to +70_C (--58_F to +158_F). If Alarm 56 is acti- vated and the primary return is the control sensor, the secondary return sensor

will be used for control if the unit is so equipped. If the unit is not equipped with a

secondary return temperature sensor or it fails, the primary supply sensor will be

used for control.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm.

AL57 Ambient Tempera- ture Sensor Failure

Alarm 57 is triggered by an ambient temperature reading outside the valid range

from --50_C (--58_F) to +70_C (+158_F).

AL58 Compressor High

Pressure Safety

Alarm 58 is triggered when the compressor high discharge pressure safety switch

remains open for at least one minute. This alarm will remain active until the pres- sure switch resets, at which time the compressor will restart.

AL59 Heat Termination

Thermostat

Alarm 59 is triggered by the opening of the heat termination thermostat and will

result in the disabling of the heater. This alarm will remain active until the thermo- stat resets.

AL60 Defrost Temperature

Sensor Failure

Alarm 60 is an indication of a probable failure of the defrost temperature sensor

(DTS). It is triggered by the opening of the heat termination thermostat (HTT) or

the failure of the DTS to go above set point within two hours of defrost initiation.

After one-half hour with a frozen range set point, or one-half hour of continuous

compressor run time, if the return air falls below 7_C (45_F), the Controller

checks to ensure the DTS reading has dropped to 10_C or below. If not, a DTS

failure alarm is given and the defrost mode is operated using the return tempera- ture sensor. The defrost mode will be terminated after one hour by the Controller.

AL61 Heaters Failure

Alarm 61 is triggered by detection of improper amperage resulting from heater

activation or deactivation. Each phase of the power source is checked for proper

amperage.This alarm is a display alarm with no resulting failure action, and will

be reset by a proper amp draw of the heater.

AL62 Compressor Circuit

Failure

Alarm 62 is triggered by improper current draw increase (or decrease) resulting

from compressor turn on (or off). The compressor is expected to draw a mini- mum of 2 amps; failure to do so will activate the alarm.This is a display alarm

with no associated failure action and will be reset by a proper amp draw of the

compressor.

AL63 Current Over Limit

Alarm 63 is triggered by the current limiting system. If the compressor is ON and

current limiting procedures cannot maintain a current level below the user se- lected limit, the current limit alarm is activated.This alarm is a display alarm and

is inactivated by power cycling the unit, changing the current limit via the code

select Cd32, or if the suction modulation valve (SMV) is open beyond the control- ler desired point.

Page 48 of 122

3-19 T-285

Table 3-6 Controller Alarm Indications (Sheet 3 of 3)

AL64 Discharge Tempera- ture Over Limit

Alarm 64 is triggered if the discharge temperature sensed is greater than 135_C

(275_F) for three continuous minutes, if it exceeds 149_C (300_F), or if the sen- sor is out of range. This is a display alarm and has no associated failure action.

AL65 Discharge Pressure

Transducer Failure

Alarm 65 is triggered by a compressor discharge transducer reading outside the

valid range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm2 (460 psig). This is a dis- play alarm and has no associated failure action.

AL66 Suction Pressure

Transducer Failure

Alarm 66 is triggered by a suction pressure transducer reading outside the valid

range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm2 (460 psig). This is a display

alarm and has no associated failure action.

AL67 Humidity Sensor

Failure

Alarm 67 is triggered by a humidity sensor reading outside the valid range of 0%

to 100% relative humidity. If alarm AL67 is triggered when the dehumidification

mode is activated, then the dehumidification mode will be deactivated.

AL68 Condenser Pressure

Transducer Failure

Alarm 68 is triggered by a condenser pressure transducer reading outside the

valid range of 73.20 cm Hg (30 in Hg) to 32.34 Kg/cm2 (460 psig). This is a dis- play alarm and has no associated failure action.

AL69 Suction Temperature

Sensor Failure

Alarm 69 is triggered by a suction temperature sensor reading outside the valid

range of --60_C (--76_F) to 150_C (302_F). This is a display alarm and has no

associated failure action.

NOTE

If the Controller is configured for four probes without a DataCORDER, the DataCORDER alarms AL70 and

AL71 will be processed as Controller alarms AL70 and AL71.

The Controller performs self-check routines. if an internal failure occurs, an

“ERR” alarm will appear on the display. This is an indication the Controller needs

to be replaced.

ERROR DESCRIPTION

ERR 0 -- RAM failure Indicates that the Controller working memory has

failed.

ERR Internal

Microprocessor

ERR 1 -- Program

Memory failure Indicates a problem with the Controller program. ERR

# Microprocessor

Failure ERR 2 -- Watchdog

time--out

The Controller program has entered a mode where- by the Controller program has stopped executing.

ERR 3 -- On board timer

failure

The on board timers are no longer operational.

Timed items such as; defrost, etc. may not work.

ERR 4 -- Internal counter

failure

Internal multi-purpose counters have failed. These

counters are used for timers and other items.

ERR 5 -- A-D failure The Controller’s Analog to Digital (A-D) converter

has failed.

Entr

StPt

Enter Setpoint

(Press Arrow &

Enter)

The Controller is prompting the operator to enter a set point.

Low Main Voltage

(Function Codes

Cd27--38 disabled

and NO alarm

stored.)

This message will be alternately displayed with the set point whenever the supply

voltage is less than 75% of its proper value.

Page 49 of 122

T-285 3-20

Table 3-7 Controller Pre-Trip Test Codes (Sheet 1 of 4)

Code

No. TITLE DESCRIPTION

NOTE

“Auto” or “Auto1” menu includes the: P, P1, P2, P3, P4, P5, P6 and rSLts. “Auto2” menu in- cludes P, P1, P2, P3, P4, P5, P6, P7, P8, P9, P10 and rSLts.“Auto3 menu includes P, P1, P2,

P3, P4, P5, P6, P7, P8 and rSLts

P Pre-Trip Initiated

All lights and display segments will be energized for five seconds at the start of

the pre-trip. Since the unit cannot recognize lights and display failures, there are

no test codes or results associated with this phase of pre-trip.

P1-0 Heaters Turned On

Setup: Heater must start in the OFF condition, and then be turned on. A current

draw test is done after 15 seconds.

Pass/Fail Criteria: Passes if current draw change is within the range specified.

P1-1 Heaters Turned Off

Setup: Heater must start in the ON condition, and then be turned off. A current

draw test is done after 10 seconds.

Pass/Fail Criteria: Passes if current draw change is within the range specified.

P2-0 Condenser Fan On

Requirements: Water pressure switch (WP) input must be closed.

Setup: Condenser fan is turned ON, a current draw test is done after 15 sec- onds.

Pass/Fail Criteria: Passes if current draw change is within the range specified.

P2-1 Condenser Fan Off

Setup: Condenser fan is turned OFF, a current draw test is done after 10 sec- onds.

Pass/Fail Criteria: Passes if current draw change is within the range specified.

P3 Low Speed Evapo- rator Fans

Requirements: The unit must be equipped with a low speed evaporator fan, as

determined by the Evaporator Fan speed select configuration variable.

NOTE

If the unit is configured for single evaporator fan operation, Pre-Trip tests

P3-0, P3-1, P4-0 and P4-1 will fail immediately if Controller alarm codes

AL11 or AL12 are active at the start of testing.

P3-0 Low Speed Evapo- rator Fan Motors On

Setup: The high speed evaporator fans will be turned on for 10 seconds, then off

for two seconds, then the low speed evaporator fans are turned on. A current

draw test is done after 60 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test.

P3-1 Low Speed Evapo- rator Fan Motors Off

Setup: The low speed Evaporator Fan is turned off, a current draw test is done

after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test.

P4-0 High Speed Evapo- rator Fan Motors On

Setup: The high speed Evaporator Fan is turned on, a current draw test is done

after 60 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test.

P4-1 High Speed Evapo- rator Fan Motors Off

Setup: The high speed Evaporator Fan is turned off, a current draw test is done

after 10 seconds.

Pass/Fail Criteria: Passes if change in current draw is within the range speci- fied. Fails if AL11 or AL12 activates during test.

P5-0 Supply/Return Probe

Test

Setup: The High Speed Evaporator Fan is turned on and run for eight minutes,

with all other outputs de-energized.

Pass/Fail Criteria: A temperature comparison is made between the return and

supply probes.

NOTE

If this test fails, “P5-0” and “FAIL” will be displayed. If both Probe tests (this

test and the PRIMARY/ SECONDARY) pass, the display will read “P5”

“PASS.”

Page 50 of 122

3-21 T-285

Table 3-7 Controller Pre-Trip Test Codes (Sheet 2 of 4)

P5-1 Supply Probe Test

Requirements: For units equipped with secondary supply probe only.

Pass/Fail Criteria: The temperature difference between primary and secondary

probe (supply) is compared.

NOTE

If this test fails, “P5-1” and FAIL will be displayed. If both Probe tests (this

and the SUPPLY/ RETURN TEST) pass, because of the multiple tests, the

display will read ’P 5’ ’PASS’.

P5-2 Return Probe Test

Requirements: For units equipped with secondary return probe only.

Pass/Fail Criteria: The temperature difference between primary and secondary

probe (return) is compared.

NOTES

1. If this test fails, “P5-2” and “FAIL” will be displayed. If both Probe tests

(this test and the SUPPLY/ RETURN) pass, because of the multiple

tests, the display will read “P 5,” “PASS.”

2. The results of Pre-Trip tests 5-0, 5-1 and 5-2 will be used to activate or

clear control probe alarms.

P-6 Not Applicable

P6-0 Compressor On

Setup: A current draw test is performed before the compressor is started. The

compressor is started. SMV is opened and another current draw test is per- formed.

Pass/Fail Criteria: Passes if the change in compressor current draw is within the

specified range.

P6--H & P6L Not Applicable

P6-2

Suction Modulation

Valve (Open and

Closed)

Setup: The compressor and fans continue to run from the previous test. The

quench valve (if configured) will operate as in normal control mode. The SMV is

closed to 0% open, current and condenser pressure readings are taken. The

SMV is opened to 50% with continuous current and condenser pressure read- ings taken to establish maximum values. The SMV is returned to 0% open and

final readings are taken.

Pass/Fail Criteria: Passes if the calculated difference in current at the 50%

open position are above a specified value before and after opening of the SMV,

OR the calculated difference in condenser pressure at the 50% open position are

above a specified value before and after opening of the SMV

P6-3 Quench Valve Test

Setup: The compressor suction temperature is measured with the Quench valve

closed. The Quench valve is energized and the suction temperature drop is

checked.

Pass/Fail Criteria: Passes if suction temperature is within the valid range.

P6-4 Not Applicable Not Used

P6-5 Not Applicable Not Used

NOTE

P7-0 & P8 are included with the “Auto2 & Auto 3” only. P9-0 through P10 are included with “Auto2” only

P7--0 High Pressure

Switch Closed

Setup: When the unit is running, the condenser fan is de-energized, and a 15

minute timer is started. The right display shows discharge pressure if the unit is

equipped with a discharge pressure transducer (DPT). If no DPT is installed, the

condenser pressure transducer (CPT) reading will be displayed.

Pass/Fail Criteria: The test fails if high pressure switch fails to open in 15 min- utes.

Page 51 of 122

T-285 3-22

Table 3-7 Temperature Controller Pre-Trip Test Codes (Sheet 3 of 4)

Note, this test is skipped if the unit does NOT have:

A compressor discharge sensor (CPDS).

A discharge pressure transducer (DPT).

Condenser pressure transducer (CPT).

In addition, this test is skipped if:

The sensed ambient temperature is less than 7_C (45_F).

The return air temperature is less than --17.8_C (0_F).

The water pressure switch (WP) is open, indicating that the unit is operating

with a water-cooled condenser.

P7-0

High Pressure

Switch Closed

(Continued)

Pass/Fail Criteria: Under conditions of the above NOTE; the test immediately

fails if the following inputs are sensed to be invalid:

Compressor discharge sensor (CPDS).

Discharge pressure transducer (DPT).

Condenser pressure transducer (CPT).

OR, if any one of the following inputs are sensed to be invalid:

Return temperature sensor (RTS).

Ambient sensor (AMBS).

In addition, the test will fail if:

The high pressure switch (HPS) fails to open within 15 minutes.

The discharge temperature exceeds 138_C (280_F).

The discharge temperature is less than or equal to ambient temperature

plus 5_C (9_F).

The condenser pressure transducer (CPT) or discharge pressure transduc- er (DPT) pressure exceeds 27.42 kg/cm2 (390 psig).

P7-1 High Pressure

Switch Open

Requirements: Test P7-0 must pass for this test to execute. Setup: The con- denser fan is started and a 60 second timer is started.

Pass/Fail Criteria: Passes the test if the high pressure switch (HPS) closes

within the 60 second time limit, otherwise, it fails.

P8-0 Perishable Mode

Heat Test

Setup: If the container temperature is below 15.6°C (60_F), the set point is

changed to 15.6°C, and a 60 minute timer is started. The left display will read

“P8-0.” The control will then heat the container until 15.6°C is reached. If the

container temperature is above 15.6°C at the start of the test, then the test pro- ceeds immediately to test P8-1 and the left display will change to “P8-1.”

Pass/Fail Criteria: The test fails if the 180 minute timer expires before the con- trol temperature reaches set point. The display will read “P8-0,” “FAIL.”

P8-1 Perishable Mode

Pull Down Test

Requirements: Control temperature must be at least 15.6°C (60_F).

Setup: The set point is changed to 0°C (32_F), and a 180 minute timer is

started. The left display will read “P8-1,” the right display will show the supply air

temperature. The unit will then start to pull down the temperature to the 0°C set

point.

Pass/Fail Criteria: The test passes if the container temperature reaches set

point before the 180 minute timer expires.

Page 52 of 122

3-23 T-285

Table 3-7 Controller Pre-Trip Test Codes (Sheet 4 of 4)

P8-2

Perishable Mode

Maintain Tempera- ture Test

Requirements: Test P8-1 must pass for this test to execute.

Setup: The left display will read “P8-2,” and the right display will show the supply

air temperature. A 60 minute timer is started. The unit will be required to main- tain the 0°C temperature to within + or -- 0.5_C (0.9_F) of set point until a Data- CORDER recording is executed. The recorder supply probe temperature running

total (and its associated readings counter) will be zeroed out for the remainder of

the recording period at the start of this test, so that the actual value recorded in

the DataCORDER will be an average of only this test’s results. Once a recording

interval is complete, the average recorder supply temperature will be recorded in

the DataCORDER, as well as stored in memory for use in applying the test pass/

fail criteria.

Pass/Fail Criteria: If the recorded temperature is within +/-- 0.5_C. of set point

from test start to DataCORDER recording, the test passes. If the average tem- perature is outside of the tolerance range at the recording, the test fails.

P9-0 Defrost Test

Setup: The defrost temperature sensor (DTS) reading will be displayed on the

left display. The right display will show the supply air temperature. The unit will

run FULL COOL for 30 minutes maximum until the DTT is considered closed.

Once the DTT is considered closed, the unit simulates defrost by running the

heaters for up to two hours, or until the DTT is considered open.

Pass/Fail Criteria: The test fails if: the DTT is not considered closed after the 30

minutes of full cooling, HTT opens when DTT is considered closed or if return air

temperature rises above 248_C (120_F).

P10-0 Frozen Mode

Setup Test

Setup: After completion of the defrost test, the testing proceeds directly to test

P10--1 if the container temperature is above 7_C (45_F). If the container temper- ature is below 7_C, a 180 minute timer will be started, the set point will be set to

7_C and the control will be placed in normal heat. The left display will read

“P10--0” and the unit will continue in operation until the temperature is raised to

set point.

Pass/Fail Criteria: If the temperature does not reach set point(less --0.3_C or

6.7 F) before the timer times out display will read “P100,” “FAIL”. The test will not

auto--repeat.

P10-1 Frozen Mode (Pull

Down) Test

Setup: When the container temperature is greater than or equal to the 7.2°C

(45_F) set point which was set in the frozen mode heat test, the left display will

read “P10--1” and the right display will show the return air temperature. The set

point will then be changed to --17.7_C (0_F). The unit will then have a maximum

of three hours to pull the container temperature down to the --17.7°C set point.

Pass/Fail Criteria: If this occurs within the three hour time limit, the test passes.

If pulldown is not completed within the three hour time, the test fails.

P10-2

Frozen Mode Main- tain Temperature

Test

Setup: After the unit has successfully completed frozen pulldown test, the left

display will read “P10--2” and the right display will show return air temperature.

The unit will then be required to maintain --17.7°C (0_F) temperature within +/--

0.5_C (0.9_F) of set point until a DataCORDER recording is executed. The

recorder return probe temperature running total (and its associated counter) will

be zeroed for the remainder of the recording period at the start of this test, so

that the actual recorded value will be an average of only this test’s results. Once

the recording interval is complete, the average return temperature will be

recorded in the DataCORDER, and stored in memory for use in applying the test

pass/fail criteria.

Pass/Fail Criteria: If the recorded temperature is within +/-- 0.5_C of set point

from test start to DataCORDER recording, the test passes. If temperature is out- side of the tolerance range at the DataCORDER recording, the test fails.

Page 53 of 122

T-285 3-24

Table 3-8 DataCORDER Function Code Assignments

NOTE

Inapplicable Functions Display “-- -- -- -- --”

To Access: Press ALT. MODE key

Code

No. TITLE DESCRIPTION

dC1 Recorder Supply

Temperature Current reading of the supply recorder sensor.

dC2 Recorder Return

Temperature Current reading of the return recorder sensor.

dC3-5 USDA 1,2,3 Temper- atures Current readings of the three USDA probes.

dC6-13 Network Data

Points 1-8

Current values of the network data points (as configured). Data point 1 (Code

6) is generally the humidity sensor and its value is obtained from the Control- ler once every minute.

dC14 Cargo Probe 4 Tem- perature Current reading of the cargo probe #4.

dC15-19 Future Expansion These codes are for future expansion, and are not in use at this time.

dC20-24 Temperature Sen- sors 1-5 Calibration

Current calibration offset values for each of the five probes: supply, return,

USDA #1, #2, and #3. These values are entered via the interrogation pro- gram.

dC25 Future Expansion This code is for future expansion, and is not in use at this time..

dC26,27 S/N, Left 4, Right 4

The DataCORDER serial number consists of eight characters. Function code

dC26 contains the first four characters. Function code dC27 contains the last

four characters. (This serial number is the same as the Controller serial num- ber)

dC28 Minimum Days Left An approximation of the number of logging days remaining until the Data- CORDER starts to overwrite the existing data.

dC29 Days Stored Number of days of data that are currently stored in the DataCORDER.

dC30 Date of last Trip start

The date when a Trip Start was initiated by the user. In addition, if the system

goes without power for seven continuous days or longer, a trip start will auto- matically be generated on the next AC power up.

dC31 Battery Test

Shows the current status of the optional battery pack.

PASS: Battery pack is fully charged.

FAIL: Battery pack voltage is low.

dC32 Time: Hour, Minute Current time on the real time clock (RTC) in the DataCORDER.

dC33 Date: Month, Day Current date (month and day) on the RTC in the DataCORDER.

dC34 Date: Year Current year on the RTC in the DataCORDER.

dC35 Cargo Probe 4

Calibration

Current calibration value for the Cargo Probe. This value is an input via the

interrogation program.

Page 54 of 122

3-25 T-285

Table 3-9 DataCORDER Pre-Trip Result Records

Test

No. TITLE DATA

1-0 Heater On Pass/Fail/Skip Result, Change in current for Phase A, B and C

1-1 Heater Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

2-0 Condenser Fan On Pass/Fail/Skip Result, Water pressure switch (WPS) -- Open/Closed,

Change in currents for Phase A, B and C

2-1 Condenser Fan Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

3-0 Low Speed Evaporator Fan

On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

3-1 Low Speed Evaporator Fan

Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

4-0 High Speed Evaporator Fan

On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

4-1 High Speed Evaporator Fan

Off Pass/Fail/Skip Result, Change in currents for Phase A, B and C

5-0 Supply/Return Probe Test Pass/Fail/Skip Result, STS, RTS, SRS and RRS

5-1 Secondary Supply Probe Test Pass/Fail/Skip Result

5-2 Secondary Return Probe Test Pass/Fail/Skip Result

6-0 Compressor On Pass/Fail/Skip Result, Change in currents for Phase A, B and C

6-1 Not Applicable Not Used

6-2 Suction Modulation Valve

Open and Closed Pass/Fail/Skip Result, Is current or pressure limit in effect (Y,N)

6-4 Not Applicable Not Used

6-5 Not Applicable Not Used

7-0 High Pressure Switch Closed Pass/Fail/Skip Result, AMBS, DPT or CPT (if equipped)

Input values that component opens

7-1 High Pressure Switch Open Pass/Fail/Skip Result, STS, DPT or CPT (if equipped)

Input values that component closes

8-0 Perishable Heat Pass/Fail/Skip Result, STS, time it takes to heat to 16_C (60_F)

8-1 Perishable Pull Down Pass/Fail/Skip Result, STS, time it takes to pull down to 0_C (32_F)

8-2 Perishable Maintain Pass/Fail/Skip Result, Averaged DataCORDER supply temperature

(SRS) over last recording interval.

9-0 Defrost Test Pass/Fail/Skip Result, DTS reading at end of test, line voltage, line

frequency, time in defrost.

10-0 Frozen Mode Set-up Pass/Fail/Skip Result, STS, time unit is in heat.

10-1 Frozen Mode Pull Down Pass/Fail/Skip Result, STS, time to pull down unit to --17.8_C (0_F).

10-2 Frozen Mode Maintain Pass/Fail/Skip Result, Averaged DataCORDER return temperature

(RRS) over last recording interval.

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T-285 3-26

Table 3-10 DataCORDER Alarm Indications

To Access: Press ALT. MODE key

Code No. TITLE DESCRIPTION

dAL70 Recorder Supply Tem- perature Out of Range

The supply recorder sensor reading is outside of the range of --50_C to

70_C (--58_F to +158_F) or, the probe check logic has determined there is

a fault with this sensor.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm.

dAL71 Recorder Return Tem- perature Out of Range

The return recorder sensor reading is outside of the range of --50_C to

70_C (--58_F to +158_F) or, the probe check logic has determined there is

a fault with this sensor.

NOTE

The P5 Pre-Trip test must be run to inactivate the alarm.

dAL72-74 USDA Temperatures

1, 2, 3 Out of Range

The USDA probe temperature reading is sensed outside of --50 to 70°C

(--58 to 158°F) range.

dAL75 Cargo Probe 4 Out of

Range

The cargo probe temperature reading is outside of --50 to 70°C (--58 to

158°F) range.

dAL76, 77 Future Expansion These alarms are for future expansion, and are not in use at this time.

dAL78-85 Network Data Point

1 -- 8 Out of Range

The network data point is outside of its specified range. The DataCORD- ER is configured by default to record the supply and return recorder sen- sors. The DataCORDER may be configured to record up to 8 additional

network data points. An alarm number (AL78 to AL85) is assigned to each

configured point. When an alarm occurs, the DataCORDER must be inter- rogated to identify the data point assigned. When a humidity sensor is

installed, it is usually assigned to AL78.

dAL86 RTC Battery Low The Real Time Clock (RTC) backup battery is too low to adequately main- tain the RTC reading.

dAL87 RTC Failure An invalid date or time has been detected. This situation may be corrected

by changing the Real Time Clock (RTC) to a valid value using DataLINE.

dAL88 DataCORDER

EEPROM Failure A write of critical DataCORDER information to the EEPROM has failed.

dAL89 Flash Memory Error An error has been detected in the process of writing daily data to the non- volatile FLASH memory.

dAL90 Future Expansion This alarm is for future expansion, and is not in use at this time.

dAL91 Alarm List Full The DataCORDER alarm queue is determined to be full (eight alarms).

Page 56 of 122

4-1 T-285

SECTION 4

OPERATION

4.1 INSPECTION (Before Starting)

WARNING

Beware of unannounced starting of the

evaporator and condenser fans. The unit

may cycle the fans and compressor unex- pectedly as control requirements dictate.

a. If container is empty, check inside for the following:

1. Check channels or “T” bar floor for cleanliness.

Channels must be free of debris for proper air cir- culation.

2. Check container panels, insulation and door seals

for damage. Effect permanent or temporary repairs.

3. Visually check evaporator fan motor mounting bolts

for proper securement (refer to paragraph 6.16).

4. Check for dirt or grease on evaporator fan or fan

deck and clean if necessary.

5. Check evaporator coil for cleanliness or obstruc- tions. Wash with fresh water.

6. Check defrost drain pans and drain lines for obstruc- tions and clear if necessary. Wash with fresh water.

7. Check panels on refrigeration unit for loose bolts and

condition of panels. Make sure T.I.R. devices are in

place on access panels.

b. Check condenser coil for cleanliness. Wash with

fresh water.

c. Open control box door. Check for loose electrical con- nections or hardware.

d. Check color of moisture-liquid indicator.

e. Check oil level in compressor sight glass.

4.2 CONNECT POWER

WARNING

Do not attempt to remove power plug(s) be- fore turning OFF start-stop switch (ST), unit

circuit breaker(s) and external power

source.

WARNING

Make sure the power plugs are clean and

dry before connecting to any power recep- tacle.

4.2.1 Connection To 380/460 vac Power

1. Make sure start-stop switch (ST, on control panel)

and circuit breaker (CB-1, in the control box) are in

position “0” (OFF).

2. Plug the 460 vac (yellow) cable into a de-energized

380/460 vac, 3-phase power source. Energize the

power source. Place circuit breaker (CB-1) in position

“I” (ON). Close and secure control box door

4.2.2 Connection to190/230 vac Power

An autotransformer (Figure 4-1) is required to allow

operation on nominal 230 volt power. It is fitted with a

230 vac cable and a receptacle to accept the standard

460 vac power plug. The 230 volt cable is black in color

while the 460 volt cable is yellow. The transformer may

also be equipped with a circuit breaker (CB-2). The

transformer is a step up transformer that will provide

380/460 vac, 3-phase, 50/60 hertz power to the unit

when the 230 vac power cable is connected to a

190/230 vac, 3-phase power source.

1. Make sure that the start-stop switch (ST, on control

panel) and circuit breakers CB-1 (in the control box

and CB-2 (on the transformer) are in position “0”

(OFF). Plug in and lock the 460 vac power plug at the

receptacle on the transformer

2. Plug the 230 vac (black) cable into a de-energized

190/230 vac, 3-phase power source. Energize the

power source. Set circuit breakers CB-1 and CB2 to

position “I” (ON). Close and secure control box door.

3 2

1. Dual Voltage Modular Autotransformer

2. Circuit Breaker (CB-2) 230V

3. 460 vac Power Receptacle

Figure 4-1 Autotransformer

4.3 ADJUST FRESH AIR MAKEUP VENT

The purpose of the fresh air makeup vent is to provide

ventilation for commodities that require fresh air

circulation. The vent must be closed when transporting

frozen foods.

Air exchange depends on static pressure differential,

which will vary depending on the container and how the

container is loaded.

Units may be equipped with an Vent Position Sensor

(VPS). The VPS determines the position of the fresh air

vent and sends data to the controller display.

4.3.1 Upper Fresh Air Makeup Vent

Two slots and a stop are designed into the disc for air

flow adjustments. The first slot allows for a 0 to 30% air

flow, and the second slot allows for a 30 to 100% air flow.

To adjust the percentage of air flow, loosen the wing nut

and rotate the disc until the desired percentage of air

flow matches with the arrow. Tighten the wing nut. To

Page 57 of 122

T-285 4-2

clear the gap between the slots, loosen the wing nut until

the disc clears the stop. Figure 4-2 gives air exchange

values for an empty container. Higher values can be

expected for a fully loaded container.

120

150

180

210

240

0 10 20 30 40 50 60 70 80 90 100

AIR

FLOW

(CMH) 1-!/2”

PERCENT OPEN

69NT40 FRESH AIR MAKEUP

T-BAR

2-%/8”

3”

T-BAR

ZERO EXTERNAL STATIC 50HZ

For 60HZ operation multiply curves by 1.2

Figure 4-2 Make Up Air Flow Chart

4.3.1 Fresh Air Vent Position Sensor (VPS)

The VPS allows the user to determine position of the

fresh air vent via function code 45. This function code is

accessible via the code select key.

The vent position will display for 30 seconds whenever

motion corresponding to 5 CMH (3 CFM) or greater is

detected. It will scroll in intervals of 5 CMH (3 CFM).

Scrolling to Function Code 45 will display the Fresh Air

Vent Position.

Data Recording of the Sensor Position -- The position of

the vent will be recorded in the DataCorder whenever

the unit is running under AC power and any of the

following occur:

Trip start

On every power cycle

Midnight

Manual change greater than 5 CMH (3 CFM) and

remains in that position for 5 minutes.

NOTE

The user has 5 minutes to make necessary ad- justments to the vent setting. This time begins

on the initial movement of the sensor. The vent

can be moved to any position within the 4 min- utes. On completion of the first 4 minutes, the

vent is required to remain stable for the next 4

minutes. If vent position changes are detected

during the 5 minutes stability period, an alarm

will be generated. This provides the user with

the ability to change the vent setting without

generating multiple events in the DataCorder.

4.3.2 Lower Fresh Air Makeup Vent

a. Full Open or Closed Positions

Maximum air flow is achieved by loosening the wing

nuts and moving the cover to the maximum open

position (100% position). The closed position is 0% air

flow position.The operator may also adjust the opening

to increase or decrease the air flow volume to meet the

required air flow.

b. Reduced Flow for Fresh Air Makeup

On some models the air slide is supplied with two

adjustable air control disks. The fresh air makeup can be

adjusted for (15, 35, 50 or 75) cubic meters per hour

(CMH). The air flow has been established at 60HZ

power and 2 1/2 inch T bar and with 15mm (.6 inch) H2O

external static above free blow.

Loosen the hex nut and adjust each disk to the required

air flow and tighten hex nut.

NOTE

The main air slide is in the fully closed position

during reduced air flow operation.

c. Adjustment

The air slide is supplied with two adjustable air control

discs. The fresh air makeup can be adjusted for 15, 35,

50 and 75 cubic meters per hour (CFM). The air flow has

been established at 60 Hz power, and a 2 1/2 inch T bar,

with 15 mm (0.6 inch) H2O external static above free

blow.

d. Air Sampling for Carbon Dioxide (CO2) Level

Loosen hex nuts and move the cover until the arrow on

the cover is aligned with the “atmosphere sampling port”

label. Tighten the hex nuts and attach a 3/8 hose to the

sampling port.

If the internal atmosphere content has reached an

unacceptable level, the operator may adjust the disc

opening to meet the required air flow volume to ventilate

the container.

4.4 CONNECT WATER-COOLED CONDENSER

The water-cooled condenser is used when cooling

water is available and heating the surrounding air is

objectionable, such as in a ship’s hold. If water cooled

operation is desired, connect in accordance with the

following subparagraphs.

4.4.1 Water--Cooled Condenser with Water Pres- sure Switch

a. Connect the water supply line to the inlet side of con- denser and the discharge line to the outlet side of the

condenser. (See Figure 2-5.)

b. Maintain a flow rate of 11 to 26 liters per minute (3 to 7

gallons per minute). The water pressure switch will

open to de-energize the condenser fan relay. The

condenser fan motor will stop and will remain stopped

until the water pressure switch closes.

c. To shift to air-cooled condenser operation,disconnect

the water supply and the discharge line to the water- cooled condenser. The refrigeration unit will shift to

air-cooled condenser operation when the water pres- sure switch closes.

Page 58 of 122

4-3 T-285

4.4.2 Water-Cooled Condenser with Condenser

Fan Switch

a. Connect the water supply line to the inlet side of con- denser and the discharge line to the outlet side of the

condenser. (See Figure 2-5.)

b. Maintain a flow rate of 11 to 26 lpm (3 to 7 gpm).

c. Set the condenser fan switch to position ”O”. This will

de-energize the condenser fan relay. The condenser

fan motor will stop and remain stopped until the CFS

switch is set to position ”I.”

CAUTION

When condenser water flow is below 11 lpm

(3 gpm) or when water-cooled operation is

not in use, the CFS switch MUST be set to

position ”1” or the unit will not operate

properly.

d. To shift to air-cooled condenser operation, stop the

unit, set the CFS switch to position ”I” and restart the

unit. Disconnect the water lines to the water-cooled

condenser.

4.5 CONNECT REMOTE MONITORING

RECEPTACLE

If remote monitoring is required, connect remote

monitor plug at unit receptacle. (See item 9, Figure 2-6.)

When the remote monitor plug is connected to the

remote monitoring receptacle, the following remote

circuits are energized:

CIRCUIT FUNCTION

Sockets B to A Energizes remote cool light

Sockets C to A Energizes remote defrost light

Sockets D to A Energizes remote in-range light

4.6 STARTING AND STOPPING INSTRUCTIONS

WARNING

Make sure that the unit circuit breaker(s)

(CB-1 & CB-2) and the START-STOP switch

(ST) are in the “O” (OFF) position before

connecting to any electrical power source.

4.6.1 Starting the Unit

1. With power properly applied, the fresh air damper set

and (if required) the water cooled condenser con- nected, (refer to paragraphs 4.2, 4.3 & 4.4) place the

START-STOP switch to “I” (ON).

2. Continue with Start Up Inspection, paragraph 4.7.

4.6.2 Stopping the Unit

To stop the unit, place the START-STOP switch in

position “0” (OFF).

4.7 START--UP INSPECTION

4.7.1 Physical Inspection

a. Check rotation of condenser and evaporator fans.

b. Check compressor oil level. (Refer to paragraph

6.8.6.)

4.7.2 Check Controller Function Codes

Check and, if required, reset controller Function Codes

(Cd27 through Cd39) in accordance with desired

operating parameters. Refer to paragraph 3.2.2.

4.7.3 Start Temperature Recorder

Partlow Recorders

a. Open recorder door and wind mechanical clock or

check battery of electronic recorder. Be sure key is re- turned to storage clip of mechanical recorder.

b. Lift stylus (pen) by pulling the marking tip outward un- til the stylus arm snaps into it’s retracted position.

c. Install new chart making sure chart is under the four

corner tabs. Lower the stylus until it has made contact

with the chart. Close and secure door.

Saginomiya Recorders

a. Open recorder door. Remove chart nut and platen.

Push voltage indicator test switch to check battery

condition. Replace battery if required.

b. Lift stylus (pen) by pushing in the stylus lifter and ro- tating the lifter clockwise (raising stylus at the same

time) until lifter locks in position

c. Install new chart making sure chart is under the four

corner tabs. Release stylus lifter by pushing down

and rotating lifter counterclockwise until stylus lifter

locks in position and stylus has made contact with

chart. Close and secure door.

DataCORDER

a. Check and, if required, set the DataCORDER Config- uration in accordance with desired recording parame- ter. Refer to paragraph 3.6.3.

b. Enter a “Trip Start”. To enter a “trip Start”, do the fol- lowing:

1. Depress the ALT MODE key and scroll to Code

dC30.

2. Depress and hold the ENTER key for five seconds.

3. The “Trip Start” event will be entered in the Data- CORDER.

4.7.4 Complete Inspection

Allow unit to run for 5 minutes to stabilize conditions and

perform a pre--trip diagnosis in accordance with the

following paragraph.

4.8 PRE-TRIP DIAGNOSIS

CAUTION

Pre-trip inspection should not be per- formed with critical temperature cargoes in

the container.

CAUTION

When Pre-Trip key is pressed, dehumidifi- cation and bulb mode will be deactivated.

At the completion of Pre-Trip activity, dehu- midification and bulb mode must be reacti- vated.

Pre-Trip diagnosis provides automatic testing of the unit

components using internal measurements and

comparison logic. The program will provide a “PASS” or

“FAIL” display to indicate test results.

The testing begins with access to a pre-trip selection

menu. The user may have the option of selecting one of

Page 59 of 122

T-285 4-4

three automatic tests (depending on software revision

installed). These tests will automatically perform a

series of individual pre--trip tests. The user may also

scroll down to select any of the individual tests. The

contents of the menus are as follows:

PRE-TRIP SELECTION MENU

Auto or Auto 1 Auto 2 Auto 3

P, P1, P2, P3,

P4, P5, P6,

rSLts

P, P1, P2, P3,

P4, P5, P6, P7,

P8, P9, P10,

rSLts

P, P1, P2, P3,

P4, P5, P6, P7,

P8, rSLts

A detailed description of the pre-trip test codes is listed

in Table 3-7, page 3-20. If no selection is made, the

pre-trip menu selection process will terminate

automatically. However, dehumidification and bulb

mode must be reactivated manually if required.

Scrolling down to the “rSLts” code and pressing ENTER

will allow the user to scroll through the results of the last

pre--trip testing run. If no pre--testing has been run (or an

individual test has not been run) since the unit was

powered up “--------” will be displayed.

To start a pre--trip test, do the following:

NOTE

1. Prior to starting tests, verify that unit

voltage (Function Code Cd 07) is within

tolerance and unit amperage draw

(Function Codes Cd04, Cd05, Cd06) is

within expected limits. Otherwise, tests

may fail incorrectly.

2. All alarms must be rectified and cleared

before starting tests.

3. Pre-trip diagnosis may also be initiated via

communications. The operation is the

same as for the key pad initiation described

below except that should a test fail, the

pre-trip mode will automatically terminate.

When initiated via communications, a test

may not be interrupted with an arrow key,

but the pre-trip mode can be terminated

with the PRE-TRIP key.

a. Press the PRE-TRIP key. This accesses a test selec- tion menu.

b. TO RUN AN AUTOMATIC TEST: Scroll through the

selections by pressing the UP ARROW or DOWN

ARROW keys to display AUTO, AUTO 2 or AUTO 3

as desired and then press the ENTER key.

1. The unit will execute the series of tests without any

need for direct user interface. These tests vary in

length, depending on the component under test.

2. While tests are running, “P#-#” will appear on the left

display, where the #’s indicate the test number and

sub-test. The right display will show a countdowntime

in minutes and seconds, indicating how much time

there is left remaining in the test.

CAUTION

When a failure occurs during automatic

testing the unit will suspend operation

awaiting operator intervention.

When an automatic test fails, it will be repeated once .

A repeated test failure will cause “FAIL” to be shown

on the right display, with the corresponding test num- ber to the left. The user may then press the DOWN

ARROW to repeat the test, the UP ARROW to skip to

the next test or the PRE--TRIP key to terminate test- ing. The unit will wait indefinitely, until the user manu- ally enters a command.

CAUTION

When Pre--Trip test Auto 2 runs to comple- tion without being interrupted, the unit will

terminate pre-trip and display “Auto 2”

“end.” The unit will suspend operation until

the user depresses the ENTER key!

When an Auto test runs to completion without a failu- re, the unit will exit the pre-trip mode, and return to

normal control operation. If configuration variable

CnF42 is set to IN, a datacorder trip start will be en- tered. If CnF42 is set to OUT, the trip start will not be

entered. However, dehumidification and bulb mode

must be reactivated manually if required.

c. TO RUN AN INDIVIDUAL TEST: Scroll through the

selections by pressing the UP ARROW or DOWN

ARROW keys to display an individual test code.

Pressing ENTER when the desired test code is dis- played.

1. Individually selected tests, other than the LED/Dis- play test, will perform the operations necessary to

verify the operation of the component. At the conclu- sion, PASS or FAIL will be displayed. This message

will remain displayed for up to three minutes, during

which time a user may select another test. If the

three minute time period expires, the unit will termi- nate pre-trip and return to control mode operation.

2. While the tests are being executed, the user may ter- minate the pre-trip diagnostics by pressing and hold- ing the PRE-TRIP key. The unit will then resume nor- mal operation. If the user decides to terminate a test

but remain at the test selection menu, the user may

press the UP ARROW key. When this is done all test

outputs will be de-energized and the test selection

menu will be displayed.

3. Throughout the duration of any pre-trip test except

the P-7 high pressure switch tests, the current and

pressure limiting processes are active .

d. Pre-Trip Test Results

At the end of the pre-trip test selection menu, the

message “P,” “rSLts” (pre--trip results) will be displayed.

Pressing the ENTER key will allow the user to see the

results for all subtests (i.e., 1-0, 1-1, etc). The results will

be displayed as “PASS” or “FAIL” for all the tests run to

completion since power up. If a test has not been run

since power up, “-- -- -- -- --” will be displayed. Once all

pre--test activity is completed, dehumidification and

bulb mode must be reactivated manually if required.

4.9 OBSERVE UNIT OPERATION

4.9.1 Crankcase Heater

When the crankcase heater is installed, it will be

operational whenever the compressor is off and there is

Page 60 of 122

4-5 T-285

power to the unit. The heater is connected to a set of

normally closed auxiliary contacts on the compressor

contactor.

4.9.2 Probe Check

If the DataCORDER is off, or in alarm mode the

controller will revert to a four probe configuration which

includes the DataCORDER supply and return air probes

as the secondary controller probes. The controller

continuously performs probe diagnosis testing which

compares the four probes. If the probe diagnosis result

indicates a probe problem exists, the controller will

perform a probe check to identify the probe(s) in error.

a. Probe Diagnostic Logic -- Standard

If the probe check option (controller configuration code

CnF31) is configured for standard, the criteria used for

comparison between the primary and secondary

control probes is:

1_C (1.8_F) for perishable set points or 2_C (3.6_F)

for frozen set points.

If 25 or more of 30 readings taken within a 30 minute

period are outside of the limit, then a defrost is initi- ated and a probe check is performed.

In this configuration, a probe check will be run as a part

of every normal (time initiated) defrost.

b. Probe Diagnostic Logic -- Special

If the probe check option is configured for special the

above criteria are applicable. A defrost with probe check

will be initiated if 25 of 30 readings or 10 consecutive

readings are outside of the limits

In this configuration, a probe check will not be run as a

part of a normal defrost, but only as a part of a defrost

initiated due to a diagnostic reading outside of the limits.

c.The 30 minute timer will be reset at each of the follow- ing conditions:

1. At every power up.

2. At the end of every defrost.

3. After every diagnostic check that does not fall out- side of the limits as outlined above.

d. Probe Check

A defrost cycle probe check is accomplished by

energizing just the evaporator motors for eight minutes

at the end of the normal defrost. At the end of the eight

minute period the probes will be compared to a set of

predetermined limits. The defrost indicator will remain

on throughout this period.

Any probe(s) determined to be outside the limits will

cause the appropriate alarm code(s) to be displayed to

identify which probe(s) needs to be replaced. The P5

Pre-Trip test must be run to inactivate alarms.

4.10 SEQUENCE OF OPERATION

General operation sequences for cooling, heating and

defrost are provided in the following subparagraphs.

Schematic representation of controller action are

provided in Figure 4-3 and Figure 4-4. Refer to Section

3 for detailed descriptions of special events and timers

that are incorporated by the controller in specific modes

of operation. Refer to paragraph 4.11 for emergency

modes of operation

SET POINT

FALLING

TEMPERATURE

RISING

TEMPERATURE

--1.5_C (2.7_F)

--1_C (1.8_F)

--0.5_C (0.9_F)

--0.20_C

+.20_C

+1.5_C (2.7_F)

+1_C (1.8_F)

+0.5_C (0.9_F)

HEATING HEATING

MODULATING

COOLING

AIR CIRCULATION

MODULATING

COOLING

+2.5_C (4.5_F)

Figure 4-3 Controller Operation -- Perishable Mode

Page 61 of 122

T-285 4-6

AIR

CIRCULATION

ONLY

SET POINT

FALLING

TEMPERATURE

RISING

TEMPERATURE

--1.5_C (2.7_F)

--1_C (1.8_F)

--0.5_C (0.9_F)

--0.20_C

+.20_C

+1.5_C (2.7_F)

+1_C (1.8_F)

+0.5_C (0.9_F)

COOLING

AIR

CIRCULATION

ONLY

COOLING

Figure 4-4 Controller Operation -- Frozen Mode

CONTROL TRANSFORMER

POWER TO

CONTROLLER

SIGNAL TO

CONTROLLER

SIGNAL TO

CONTROLLER

ENERGIZED

DE--ENERGIZED

FOR FULL DIAGRAM AND

LEGEND, SEE SECTION 7

NOTE: HIGH SPEED EVAPORATOR FAN SHOWN. FOR LOW SPEED

CONTACT TE IS DE--ENERGIZED AND CONTACT TV IS ENERGIZED

Figure 4-5 Perishable Mode Cooling

4.10.1 Sequence Of operation -- Perishable Mode

Cooling

NOTE

In the Conventional Perishable Mode of opera- tion the evaporator motors run in high speed. In

the Economy Perishable Mode the fan speed is

varied.

NOTE

In low temperature ambients the condenser fan

will be cycled by the controller to maintain prop- er condensing pressure.

a. With supply air temperature above set point and de- creasing, the unit will be cooling with the condenser

fan motor (CF), compressor motor (CH), evaporator

fan motors (EF) energized and the COOL light illumi- nated. (See Figure 4-5.)

b. When the air temperature decreases to a predeter- mined tolerance above set point, the in-range light is

illuminated.

c. As the air temperature continues to fall, modulating

cooling starts at approximately 2.5_C (4.5_F) above

set point. (See Figure 4-3)

d. The controller monitors the supply air. Once the sup- ply air falls below set point and 0% SMV position is

reached, the controller periodically records the sup- ply air temperature, set point and time. A calculation

is then performed by subtracting the set point reading

from the supply air and multiplying the result by the

time reading. The result is negative number.

e. When the calculation reaches --250, contacts TC and

TN are opened to de-energize compressor and con- denser fan motors. The cool light is also de-ener- gized.

f. The evaporator fan motors continue to run to circulate

air throughout the container. The in-range light re- mains illuminated as long as the supply air is within

tolerance of set point.

g. When the supply air temperature increases to 0.2_C

(0.4_F) above set point and the three minute off time

has elapsed, relays TC and TN are energizes to re- start the compressor and condenser fan motors. The

cool light is also illuminated.

Page 63 of 122

T-285 4-8

Manual Defrost/Interval key operation:

Depressing and holding the Defrost Interval key for

five (5) seconds will initiate defrost. If the defrost in- terval key is released in less than five (5) seconds,

defrost interval (code 27) shall be displayed.

2. The user sends a defrost request by communica- tions.

3. The defrost interval timer (controller function code

Cd27) reaches the defrost interval set by the user.

4. The controller probe diagnostic logic determines that

a probe check is necessary based on the tempera- ture values currently reported by the supply and re- turn probes.

5. The controller Demand Defrost configuration vari- able (CnF40) is set to “In” and the unit has been in

pull down operation for over 2.5 hours without reach- ing set point.

CONTROL TRANSFORMER

POWER TO

CONTROLLER

SIGNAL TO

CONTROLLER

SIGNAL TO

CONTROLLER

ENERGIZED

DE--ENERGIZED

FOR FULL DIAGRAM AND

LEGEND, SEE SECTION 7

SIGNAL TO

CONTROLLER

Figure 4-8 Defrost

Processing of a defrost request is controlled by the

Defrost Termination Thermostat. The Defrost

Termination Thermostat is not a physical component. It

is a software point that acts as a thermostat, allowing

defrost when it is considered “closed” and preventing or

terminating defrost when it is considered “open”. The

actual temperatures used to make the “open” or

“closed” determinations are dependent on the type of

defrost request made and the operator setting of

configuration variable CnF41. Configuration variable

CnF41may be factory set at the default value of

25.6°C(78°F) or a lower value of 18°C(64°F).

When a request for defrost is made by the use of the

Manual Defrost Switch or Communications, the unit will

enter defrost when the reading at the Defrost

Temperature Sensor is at or below the CnF41 setting.

Defrost will terminate when the Defrost Sensor

Temperature reading rises above the CnF41 setting.

When a request for defrost is made by probe check, the

unit will enter defrost when the Defrost Temperature

Sensor reading is at or below 25.6°C(78°F). The unit will

terminate defrost when the Defrost Temperature

Sensor reading rises above 25.6°C(78°F)

When a request for defrost is made by demand defrost ,

the unit will enter defrost when the reading at the Defrost

Temperature Sensor is at or below 18°C (64.4°F).

Defrost will terminate when the Defrost Sensor

Temperature reading rises above the CnF41 setting.

When a defrost has terminated, the defrost interval

timer will begin counting when the reading at the Defrost

Temperature Sensor is at or below 10°C(50°F). Once

the timer has counted the required time, the unit will

enter defrost if the Defrost Temperature Sensor is at or

below 25.6°C(78°F). Defrost will terminate when the

Defrost Sensor Temperature reading rises above the

CnF41 setting.

When the unit enters defrost, the controller opens

contacts TC, TN and TE (or TV) to de-energize the

compressor, condenser fan and evaporator fans. (See

Figure 4-8.) The COOL light is also de--energized.

The controller then closes TH to supply power to the

heaters. The defrost light is illuminated.

When the defrost temperature sensor reading rises to

the applicable Defrost Termination Thermostat

“opening” point the de--icing operation is terminated.

If defrost does not terminate correctly and temperature

reaches the set point of the heat termination thermostat

(HTT) the thermostat will open to de--energize the

heaters. If termination does not occur within 2.0 hours,

the controller will terminate defrost. An alarm will be

given of a possible DTS failure.

If probe check (controller function code CnF31) is

configured to special, the unit will proceed to the next

operation (snap freeze or terminate defrost). If the code

is configured to standard, the unit will perform a probe

check. The purpose of the probe check is to detect

malfunctions or drift in the sensed temperature that is

too small to be detected by the normal sensor out of

range tests. The system will run for eight minutes in this

condition. At the end of the eight minutes, probe alarms

will be set or cleared based on the conditions seen.

When the return air falls to 7_C (45_F), the controller

checks to ensure the defrost temperature sensor (DTS)

reading has dropped to 10_C or below. If it has not, a

DTS failure alarm is given and the defrost mode is

operated by the return temperature sensor (RTS).

If controller function code CnF33 is configured to snap

freeze, the controller will sequence to this operation.

The snap freeze consists of running the compressor

without the evaporator fans in operation for a period of

four minutes with the suction modulation valve at

maximum allowed opening. When the snap freeze is

completed, defrost is formally terminated.

Page 64 of 122

4-9 T-285

4.11 EMERGENCY OPERATION

Operation by the refrigeration controller may be

overridden by use of the EMERGENCY BYPASS or by

use of the EMERGENCY DEFROST switch. The

EMERGENCY BYPASS switch functions to bypass the

controller in the event of controller failure, The

EMERGENCY DEFROST switch functions to bypass

the controller and place the unit in the defrost mode.

4.11.1 Emergency Bypass Operation.

To place the unit in the emergency bypass mode of

operation, cut the wire tie installed at the switch

mounting (see Figure 2-6) and place the switch in the

EMERGENCY BYPASS COOLING position.

The switch is a normally open four pole switch which is

placed in the EMERGENCY BYPASS COOLING

position to:

a. Provide power to the compressor contactor with the

high pressure switch and compressor motor internal

protector in line.

b. Provide power to the condenser fan motor contactor

with the water pressure switch and condenser motor

internal protector in line.

c. Provide power to the evaporator fan motor high

speed contactors with the evaporator fan motor inter- nal protectors in line.

d. Provide power to the bypass module (item15,

Figure 2-3). The bypass module supplies power to

the stepper motor drive to bring the valve to the full

open position.

CAUTION

The unit will remain in the full cooling mode

as long as the emergency bypass switch is

in the BYPASS position. If the cargo may be

damaged by low temperatures, the operator

must monitor container temperature and

manually cycle operation as required to

maintain temperature within required lim- its.

To return the unit to normal operation, place the switch in

the NORMAL OPERATION position. When emergency

oparation is no longer required, re--install the wire tie at

the switch mounting.

4.11.2 Emergency Defrost Operation.

To place the unit in the emergency defrost mode of

operation, cut the wire tie installed at the switch

mounting (see Figure 2-6) and place the switch in the

EMERGENCY DEFROST position.

NOTE

1. If the unit is in the emergency bypass

cooling mode, the emergency defrost

switch will override this mode and place the

unit in defrost.

2. The IN--RANGE LIGHT is de--energized

when in the emergency defrost mode.

The switch is a normally open four pole switch which is

placed in the EMERGENCY DEFROST position to:

a. De--energize the compressor, condenser fan and

evaporator fan contactors.

b. Illuminate the EMERGENCY DEFROST LIGHT.

c. Energize the heater contactor.

d. Illuminate the DEFROST LIGHT.

CAUTION

The unit will remain in the DEFROST mode

as long as the emergency defrost switch is

in the DEFROST position. To prevent cargo

damage, the operator must monitor con- tainer temperature and manually cycle op- eration as required to maintain temperature

within required limits.

To return the unit to normal operation, place the switch in

the NORMAL OPERATION position. When emergency

defrost is no longer required, re--install the wire tie at the

switch mounting.

Page 65 of 122

5-1 T-285

SECTION 5

TROUBLESHOOTING

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

5.1 UNIT WILL NOT START OR STARTS THEN STOPS

External power source OFF Turn on

No power to unit Start-Stop switch OFF or defective Check

No power to unit Circuit breaker tripped or OFF Check

Autotransformer not connected 4.2.2

Circuit breaker OFF or defective Check

Loss of control power

Control transformer defective Replace Loss of control power Fuse (F3) blown Check

Start-Stop switch OFF or defective Check

Evaporator fan motor internal protector open 6.16

Condenser fan motor internal protector open 6.11

Component(s) Not Operating Component(s) Not Operating Compressor internal protector open 6.8

High pressure switch open 5.7

Heat termination thermostat open Replace

Low line voltage Check

Compressor hums, but does not Single phasing Check ompressor hums, but does not

start Shorted or grounded motor windings 6.8

Compressor seized 6.8

5.2 UNIT OPERATES LONG OR CONTINUOUSLY IN COOLING

Container

Hot load (Failure to Pre--cool) Normal

Container Defective box insulation or air leak Repair

Unit in Emergency Bypass mode. 4.11.1

Shortage of refrigerant 6.7.1

Evaporator coil covered with ice 5.6

Evaporator coil plugged with debris 6.15

Evaporator fan(s) rotating backwards 6.15/6.16

Defective evaporator fan motor/capacitor 6.17

Refrigeration System Air bypass around evaporator coil Check Refrigeration System

Controller set too low Reset

Compressor service valves or liquid line shutoff valve par- tially closed

Open valves

completely

Dirty condenser 6.10

Compressor worn 6.8

Current limit (function code Cd32) set to wrong value 3.3.5

Suction modulation valve malfunction 6.18

Page 66 of 122

T-285 5-2

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

5.3 UNIT RUNS BUT HAS INSUFFICIENT COOLING

Compressor Compressor valves defective 6.8

Abnormal pressures 5.7

Controller malfunction 5.9

Refrigeration System

Evaporator fan or motor defective 6.16

Refrigeration System Suction modulation valve malfunction 6.18

Condenser Pressure Transducer defective Check

Shortage of refrigerant 6.7.1

5.4 UNIT WILL NOT HEAT OR HAS INSUFFICIENT HEATING

Start-Stop switch OFF or defective Check

No operation of any kind No operation of any kind Circuit breaker OFF or defective Check

External power source OFF Turn ON

Circuit breaker or fuse defective Replace

Control Transformer defective Replace

No control power No control power Evaporator fan internal motor protector open 6.16

Heat relay defective Check

Heater termination switch open 6.15

Heater(s) defective 6.15

Heater contactor or coil defective Replace

Evaporator fan motor(s) defective or rotating backwards 6.15/6.16

Unit will not heat or has insu U ffi- Evaporator fan motor contactor defective Replace nit will not heat or has insuffi- cient heat Controller malfunction 5.9

Defective wiring Replace

Loose terminal connections Tighten

Low line voltage 2.3

5.5 UNIT WILL NOT TERMINATE HEATING

Controller improperly set Reset

Unit fails to stop heating

Controller malfunction 5.9 Unit fails to stop heating Heater termination thermostat remains closed along with

the heat relay 6.15

5.6 UNIT WILL NOT DEFROST PROPERLY

Defrost timer malfunction (Cd27) Table 3-5

Loose terminal connections Tighten/

Will not initiate defrost

i ll

Will not initiate defrost Defective wiring Replace

automatically Defrost temperature sensor defective or heat termination

thermostat open Replace

Heater contactor or coil defective Replace

Will not initiate de W frost Manual defrost switch defective Replace ill not initiate defrost

manually Defrost temperature sensor open 4.10.4

Initiates but relay (DR) drops

out Low line voltage 2.3

Initiates but does not defrost

Heater contactor or coil defective Replace Initiates but does not defrost Heater(s) burned out 6.15

Page 67 of 122

5-3 T-285

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

5.6 UNIT WILL NOT DEFROST PROPERLY --Continued

Frequent defrost Wet load Normal

Will not terminate defrost Unit in Emergency Defrost mode 4.11.2

5.7 ABNORMAL PRESSURES (COOLING)

Condenser coil dirty 6.10

Condenser fan rotating backwards 6.11

Condenser fan inoperative 6.11

High discharge pressure High discharge pressure Refrigerant overcharge or noncondensibles 6.7.1

Discharge pressure regulator valve defective Replace

Discharge service valve partially closed Open

Suction modulation valve malfunction 6.18

Suction service valve partially closed Open

Filter-drier partially plugged 6.13

Low refrigerant charge 6.7.1

Expansion valve defective 6.14

Low suction pressure Low suction pressure No evaporator air flow or restricted air flow 6.15

Excessive frost on evaporator coil 5.6

Evaporator fan(s) rotating backwards 6.16.3

Discharge pressure regulator valve defective Replace

Suction modulation valve malfunction 6.18

Suction and discharge pres- Heat exchanger defective Replace Suction and discharge pres- sures tend to equalize when unit

i ti

q Compressor valves defective 6.8

is operating Compressor cycling/stopped Check

5.8 ABNORMAL NOISE OR VIBRATIONS

Loose mounting bolts Tighten

Worn bearings 6.8

Compressor Compressor Worn or broken valves 6.8

Liquid slugging 6.14

Insufficient oil 6.8.6

Bent, loose or striking venturi Check

Condenser or Evaporator Fan Condenser or Evaporator Fan Worn motor bearings 6.11/6.16

Bent motor shaft 6.11/6.16

5.9 CONTROLLER MALFUNCTION

Defective Sensor 6.22

Will not control Defective wiring Check

Will not control Fuse (F1, F2) blown Replace

Stepper motor suction modulation valve circuit malfunction 6.18

Page 68 of 122

T-285 5-4

CONDITION POSSIBLE CAUSE

REMEDY/

REFERENCE

SECTION

5.10 NO EVAPORATOR AIR FLOW OR RESTRICTED AIR FLOW

Evaporator coil blocked

Frost on coil 5.6

Evaporator coil blocked Dirty coil 6.15

Evaporator fan motor internal protector open 6.16

No or partial evaporator air flow

Evaporator fan motor(s) defective 6.16

No or partial evaporator air flow Evaporator fan(s) loose or defective 6.16

Evaporator fan contactor defective Replace

5.11 THERMOSTATIC EXPANSION VALVE MALFUNCTION

Low refrigerant charge 6.7.1

External equalizer line plugged Open

Wax, oil or dirt plugging valve or orifice Ice formation at

valve seat 6.14

Low suction pressure with high

superheat Superheat too high 6.7.1

superheat Power assembly failure

Loss of element/bulb charge 6 14 Broken capillary 6.14

Foreign material in valve

Hi h i i h l

Superheat setting too low 6.14

High suction pressure with low

superheat External equalizer line plugged Ice holding valve open Open superheat

Foreign material in valve 6.14

Liquid slugging in compressor Pin and seat of expansion valve eroded or held open by

foreign material

6 1

Fluctuating suction pressure

Improper bulb location or installation 6.14

Fluctuating suction pressure Low superheat setting

5.12 AUTOTRANSFORMER MALFUNCTION

Circuit breaker (CB-1 or CB-2) tripped Check

Unit will not start

Autotransformer defective 6.19

Unit will not start Power source not turned ON Check

460 VAC power plug is not inserted into the receptacle 4.2.2

5.13 WATER-COOLED CONDENSER OR WATER PRESSURE SWITCH

High discharge pressure

Dirty coil High discharge pressure 6 12 Noncondensibles 6.12

Condenser fan starts and stops

Water pressure switch malfunction Check

Condenser fan starts and stops Water supply interruption Check

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